Application: 30 kHz Ultrasonic Staking Machine
Ultrasonic staking is an excellent method of joining assemblies that are large or comprised of dissimilar materials. The typical AMS ultrasonic staking machine includes a number of important features that are essential to achieving consistent, repeatable welds cycle after cycle.
Using ultrasonic welding technology to stake plastic bosses is often cost prohibitive. However, AMS machines utilize the common sense approach of sequencing so that a few power supplies can operate a large number of actuators. This approach brings the cost of ultrasonics in line with expectations for staking applications. Additionally, AMS uses solid, wear resistant ultrasonic horns that last dramatically longer than carbide coated titanium horns. This further improves the cost effectiveness of ultrasonic staking.
The 30 kHz staking machine shown in the pictures above processed a washer/dryer door assembly that included 15 hollow bosses. 30 kHz was chosen to protect the Class A surface from weld read-through often experienced with 20 kHz systems and for its powerful ability to weld and form fully chromed bosses. Thermal and hot-air staking cannot form chromed bosses.
One dedicated actuator (with ultrasonic stack) is positioned over each boss. Each actuator includes a mechanical stop, individual pressure regulator, and weld by distance capability. This approach provides maximum weld repeatability and ensures that bosses are fully welded and formed, but not over-welded.
Rigid part hold-down clamps provide a fully compressed and tight after-weld assembly. Other features, such as the programmed ability to sequence from fewer ultrasonic power supplies thus decreasing costly spares, make for a reliable machine that exemplifies the knowledgeable approach AMS applies to each application.
Click the "T" Technology button to learn more about ultrasonic staking technology.
