Ultrasound generators for industrial applications

I ultrasound generators represent the technological heart of ultrasonic welding systems for thermoplastic materials. These devices transform electrical energy into high-frequency mechanical oscillations, activating the molecular melting process of plastic materials in a fast, precise and repeatable manner.

Within the range offered by Sonomax Srlgenerators of the SX Series are characterised by their reliability, versatility of use and compatibility with multiple welding configurations, both manual and automated. All models are digital generators, equipped with backlit display and an intuitive user interface, allowing simplified management of welding parameters.

How does an ultrasound generator work?

The generator converts alternating current (AC) from the mains into a high-frequency current, usually between 20 kHz and 40 kHz. This current is then sent to the piezoelectric transducerwhich transforms it into mechanical vibrations. The vibrations are amplified by a booster (where necessary) and transmitted to a sonotrodewhich applies them locally to the workpiece to be welded. The molecular friction produced generates enough heat to melt the plastic locally, without the need for adhesives or external heating elements.

Advantages of ultrasonic welding

• High precision and repeatability of the welded joint
• Reduced cycle timeswith welds taking place in fractions of a second
• Absence of consumablessuch as glues or solvents
• Reduced thermal impactwhich protects electronic or sensitive components
• Easy integration into automatic production lines

These advantages make ultrasonic generators ideal for the automotive, medical, packaging, filtration, textile, electronics and personal protective equipment industries.

SX generator range from Sonomax

Sonomax offers four main models of ultrasound generators, all powered by 230V (with 115V or 240V configuration available on request) and designed for optimum performance in different production contexts.

SX ECO

• Frequency: 30, 35, 40 kHz
• Power: 400 - 900 W
• Can be used with: linear actuators, pistol grips and plastic sleeve grips, manual cutting structures, cutting systems for automatic systems

SX ECO Plus

• Frequency: 20, 30, 35, 40 kHz
• Power: 400 - 3000 W
• Broad compatibility with linear actuators, manual handles and automated cutting systems

SX ECO QE

• Frequency: 20, 30, 35, 40 kHz
• Power: 400 - 3000 W
• Optimised to fit inside switchboards and used extensively in automatic systems with linear actuators

SX ULTRA

• Frequency: 20, 30, 35, 40 kHz
• Power: 400 - 3000 W
• Includes complete software for the management of PSX series weldersand the complete management of pneumatic linear actuators

All SX series models are equipped with:

• Welding time control
• Energy and amplitude regulation (30-100%)
• Counting function
• Automatic frequency control
• Overload and overheating protection
• Active ventilation and polypropylene container (on request)

Operating specifications: frequency and power

The choice of operating frequency is crucial:

• 20 kHz: deep energy penetration, suitable for robust parts and structural joints
• 30 kHz: good compromise between strength and precision
• 35 kHz: balance between mechanical performance and noise reduction
• 40 kHz: high precision and low noise impact, ideal in medical or electronic environments

In parallel, the nominal power should be selected according to the size of the sonotrode and the complexity of the application. Sonomax offers solutions from 400 to 3000 Wsufficient to cover both light and intensive applications.

Technical Standards and Quality

Sonomax generators are designed according to the principles of the Machinery 2006/42/ECof the Directive Low Voltage 2014/35/EU and the electromagnetic compatibility 2014/30/EU.

Sonomax: technical partner for industrial welding

With over 20 years of experience in ultrasonic welding of thermoplastic materials, Sonomax Srl supports designers, buyers and production managers in choosing the most suitable solution. Thanks to a flexible and customised productiongenerators can be adapted to the customer's specific needs, also developing customised sonotrodes and interfaces on request.