01
Generate
The generator supplies controlled high-frequency energy to the ultrasonic stack.
Category overview
The ultrasonic stack converts electrical energy into controlled mechanical vibration and transfers that vibration to the application tool.
Stable operation depends on matching the transducer, booster, sonotrode, fixture and generator as one complete oscillation system.
System architecture
How the Ultrasonic Stack Transfers Energy
Stable ultrasonic operation depends on the complete energy path from the generator to the supported workpiece.
02
Convert
The transducer converts electrical energy into longitudinal mechanical vibration.
03
Modify
The booster adjusts vibration amplitude and provides the mounting point for the ultrasonic stack.
04
Apply
The sonotrode delivers vibration into the product while the fixture supports the workpiece.
Ultrasonic stack
Core Elements of the Oscillation System
Each component performs a specific role in generating, modifying and delivering ultrasonic vibration to the workpiece.
ENERGY CONVERSION
Transducer
The transducer converts high-frequency electrical energy from the generator into longitudinal mechanical vibration. Frequency, cooling and housing protection must match the application and operating environment.
- Frequency: commonly 20 kHz or 35 kHz
- Operating environment: housing protection and cooling are reviewed according to load and duty cycle
COMPACT STACK
Compact Transducer-Booster Unit
A combined transducer and booster arrangement reduces installation length where machine space is limited. The final ratio and mounting method must still be matched to the tooling and process requirement.
- Architecture: integrated conversion and amplitude stage
- Best fit: compact machine layouts with limited installation space
AMPLITUDE CONTROL
Amplitude Booster
The booster modifies vibration amplitude and provides a mechanical mounting point within the ultrasonic stack. Ratio, material and stress level must be selected together with the transducer and sonotrode.
- Function: modifies amplitude and provides the stack mounting point
- Material: aluminum or titanium according to stress, duty cycle and process demand
ENERGY DELIVERY
Application Tooling
The sonotrode transfers ultrasonic vibration into the product, while the fixture supports and positions the workpiece. Geometry, contact area, material and surface treatment are developed around the actual application.
- Sonotrode: tuned to the process and contact geometry
- Fixture: supports the part and directs energy transfer
- Surface: coatings may improve wear, release or corrosion resistance
Engineering considerations
Stack Components Must Be Matched as One System
Individual parts cannot be selected reliably without considering the complete resonant assembly.
FREQUENCY
Resonance Matching
The transducer, booster and sonotrode must operate within the same designed frequency range as one resonant assembly.
AMPLITUDE
Amplitude & Mechanical Stress
Higher amplitude is not automatically better. The selected ratio, material and tooling geometry must remain within an acceptable mechanical stress range.
TOOLING
Tooling & Material Design
Sonotrode geometry, fixture support and component material must be developed around the part, contact area, wear conditions and duty cycle.
FAQ
Ultrasonic Stack Components FAQ
Practical questions about replacement components, compatibility and application tooling.
Individual components can be supplied where suitable, but frequency, interface dimensions, amplitude, generator compatibility and stack resonance must first be reviewed.
No. Physical dimensions are only part of the review. Frequency, thread interfaces, amplitude ratio, mass distribution and compatibility with the existing stack must also be confirmed.
The sonotrode delivers vibration while the fixture supports the part. Poor support can reduce energy transfer, create marking or make the process unstable.
ENGINEERING SUPPORT
Discuss Your Ultrasonic Stack Configuration
Let us review how the transducer, booster, sonotrode, fixture and generator should work together as one resonant system.
Discuss an Ultrasonic Application