10kW industrial ultrasonic welder design

As the problem of final joining quality and environmental pollutants such as lead and toxic gases, the ultrasonic welding system is used increasingly in the industrial workspace. The ultrasonic welder is composed of the inverter, L-C filter for the mechanical oscillation to piezoelectric, booster and horn for amplification of mechanical displacement. Also the resonant frequency is changing by design of mechanical structure and characteristic of bonding material, therefore the PLL technique is required for controlling resonant frequency by digital controller. In this paper, inverter used 10kW full bridge and LC filter are simulated using PSIM software. Also, the hardware of ultrasonic welder and software for controlling resonant frequency are verified through the experiments.