Ultrasonic welding tool and welding method for curved flexible products

Abstract

The present invention relates to an ultrasonic welding tool and a welding method for arc-surface flexible products. The ultrasonic welding tool for arc-surface flexible products in the present invention comprises a base, a frame, an upper slide rail, a lower slide rail, an upper sliding electric cylinder, a lower sliding electric cylinder, an upper telescopic rod, a lower telescopic rod, a hydraulic cylinder, a hydraulic telescopic rod, an ultrasonic generator and a transducer and a horn. The upper telescopic rod and the lower telescopic rod are provided with pulley assemblies at opposite ends. The product to be welded is clamped between the pulley assemblies on the upper telescopic rod and the lower telescopic rod. The hydraulic telescopic rod presses the product down until it is pressed against the welding head to complete the welding of a point. Compared with the prior art, the present invention can adaptively match the arc-surface flexible products to be welded, and then can automatically feed materials according to a preset program, so as to obtain a precise welding path and a regular welding gap, improve the sealing quality of the welding site, and significantly improve the stability of welding.

Description

Technical Field

[0001] The present invention relates to a welding tooling, and more particularly to an ultrasonic welding tooling and a welding method for arc-shaped flexible products. Background Art

[0002] Ultrasonic welding converts 50 / 60 Hz current into electrical energy of 15, 20, 30 or 40 KHz through an ultrasonic generator. The converted high-frequency electrical energy is again converted into mechanical motion of the same frequency through a transducer, and then the mechanical motion is transmitted to the welding head through a horn device that can change the amplitude. The welding head transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy by friction to melt the plastic. When ultrasonic waves act on the thermoplastic plastic contact surface, high-frequency vibrations of tens of thousands of times per second will be generated. This high-frequency vibration with a certain amplitude transmits ultrasonic energy to the welding area through the upper workpiece. Since the acoustic resistance is large at the welding area, that is, at the interface of the two welds, local high temperature will be generated. Also, due to the poor thermal conductivity of the plastic, it cannot be dissipated in time for a while and accumulates in the welding area, causing the contact surfaces of the two plastics to quickly melt. With a certain pressure applied, they are fused into one body. When the ultrasonic action stops, the pressure is maintained for a few seconds to make it solidify and form, thus forming a strong molecular chain to achieve the purpose of welding, and the welding strength can be close to the strength of the raw material. The quality of ultrasonic plastic welding depends on three factors: the amplitude of the transducer welding head, the applied pressure, and the welding time. The welding time and the welding head pressure can be adjusted, and the amplitude is determined by the transducer and the horn.

[0003] Existing ultrasonic welding machines all require manual feeding. During the manual delivery process of the arc-shaped flexible products to be welded, due to the difficulty in controlling the delivery rate, the welding spacing is usually uneven and the welding edge trajectory is messy, resulting in unstable product quality after manual welding and poor aesthetics at the same time.

[0004] CN205464790U discloses an ultrasonic welding machine and its clamping device. The clamping device includes a guide rail and a clamping mechanism. Among them, the guide rail is fixedly installed on the base of the ultrasonic welding machine, and a male groove is provided on the guide rail. The clamping mechanism includes a stop block, a bolt, and an adjustment handle. The stop block is fixedly installed on the head of the ultrasonic welding machine, and a female groove is provided on the stop block. The female groove is fitted with the male groove. The bolt includes a fixed part and a connecting part. The fixed part is adjacent to the first surface of the stop block, and the connecting part passes through the stop block. The adjustment handle includes an adjustment part and a locking part. The locking part is threadedly connected to the connecting part, and the locking part abuts against the second surface of the stop block. This technical solution still cannot solve the problem of automatic feeding and automatic welding process of flexible products to be welded, resulting in uneven welding quality. Summary of the Invention

[0005] The object of the present invention is to overcome the defects of the above-mentioned existing technologies and provide an ultrasonic welding tooling and a welding method for arc-shaped flexible products. The ultrasonic welding tooling in the present invention can adaptively match the arc-shaped flexible products to be welded, and then can automatically feed the materials according to a preset program, obtaining a precise welding path and a regular welding gap, significantly improving the welding stability while enhancing the tightness quality of the welding sites.

[0006] The object of the present invention can be achieved through the following technical solutions:

[0007] The ultrasonic welding tooling for arc-shaped flexible products in the present invention includes a base, a frame, an upper slide rail, a lower slide rail, an upper sliding electric cylinder, a lower sliding electric cylinder, an upper telescopic rod, a lower telescopic rod, a hydraulic cylinder, a hydraulic telescopic rod, an ultrasonic generator, a transducer and a horn. Specifically:

[0008] The frame is arranged on the base;

[0009] The upper slide rail is arranged on the frame;

[0010] The lower slide rail is arranged on the base;

[0011] The upper sliding electric cylinder is arranged on the upper slide rail, and the upper sliding electric cylinder can be displaced along the upper slide rail;

[0012] The lower sliding electric cylinder is arranged on the lower slide rail, and the lower sliding electric cylinder can be displaced along the lower slide rail;

[0013] The upper telescopic rod and the lower telescopic rod are respectively connected to the upper sliding electric cylinder and the lower sliding electric cylinder. Pulley assemblies are provided at the opposite ends of the upper telescopic rod and the lower telescopic rod, and the product to be welded is clamped between the pulley assemblies on the upper telescopic rod and the lower telescopic rod;

[0014] The hydraulic cylinder is arranged on the frame;

[0015] The hydraulic telescopic rod is connected to the hydraulic cylinder;

[0016] The ultrasonic generator is arranged on the base;

[0017] The transducer and the horn are connected to the ultrasonic generator. A welding head is provided at the end of the horn. The welding head is located below the hydraulic telescopic rod. The hydraulic telescopic rod presses down the product until it presses against the welding head to complete the welding of one point. Then, the pulley assemblies on the upper telescopic rod and the lower telescopic rod rotate synchronously to deliver the product forward by a preset distance for the welding of the next point.

[0018] Further, a horizontal working platform is provided on the frame;

[0019] The upper sliding rail is provided on the lower surface of the horizontal working platform;

[0020] The upper end of the upper sliding electric cylinder is movably limited within the upper sliding rail;

[0021] The upper sliding electric cylinder can adjust its horizontal position along the upper sliding rail.

[0022] Further, the lower sliding rail is provided on the upper surface of the base;

[0023] The lower end of the lower sliding electric cylinder is movably limited within the lower sliding rail;

[0024] The lower sliding electric cylinder can adjust its horizontal position along the lower sliding rail.

[0025] Further, racks are provided on both the upper sliding rail and the lower sliding rail;

[0026] Gears matching the tooth patterns on the racks are provided on both the upper sliding electric cylinder and the lower sliding electric cylinder;

[0027] First servo motors drivingly connected to the gears are further provided on the upper sliding electric cylinder and the lower sliding electric cylinder. The gears are driven by the first servo motors, thereby enabling the upper sliding electric cylinder and the lower sliding electric cylinder to perform horizontal displacement according to instructions.

[0028] Further, the pulley assembly includes a pulley and a second servo motor drivingly connected to the pulley.

[0029] Further, the welding tooling further includes a microprocessor;

[0030] The microprocessor is electrically connected to the first servo motor, the second servo motor, the ultrasonic generator, and the hydraulic cylinder respectively;

[0031] The microprocessor issues command signals to the first servo motor and the second servo motor according to a preset program, and controls the first servo motor and the second servo motor to perform programmed torque output.

[0032] Further, the electrical connection is a wired connection or a wireless connection;

[0033] The ultrasonic welding tooling further includes a touch display screen, and the touch display screen is electrically connected to the microprocessor to achieve human-machine interaction.

[0034] Further, the product is a plastic product with a curved and flexible surface.

[0035] Further, the microprocessor is an ARM processor.

[0036] Further, the welding tooling further includes pressure sensors disposed on the pulley assemblies. Each pressure sensor can sense the pressure value on each pulley assembly and feedback it to the microprocessor for comparison, so as to further adjust the pressure and make the pressure values at each site the same.

[0037] The method for welding an arc-shaped flexible product by applying the above ultrasonic welding tooling in the present invention includes the following steps:

[0038] S1: Set the feeding program and the ultrasonic welding program according to the arc size of the product;

[0039] S2: The microprocessor instructs the first servo motor to perform programmed torque output according to the preset feeding program, so as to adjust the horizontal positions of the upper sliding cylinder and the lower sliding cylinder. At the same time, it instructs the upper sliding cylinder and the lower sliding cylinder to perform thrust output, so as to control the elongation amounts of the upper telescopic rod and the lower telescopic rod, so that the product to be welded can be clamped between the pulley assemblies on the upper telescopic rod and the lower telescopic rod in a matching manner;

[0040] S3: The microprocessor instructs the second servo motor to perform programmed torque output according to the preset ultrasonic welding program, and instructs the hydraulic cylinder to perform programmed pressure output, so that the hydraulic telescopic rod presses down the product until it presses against the welding head, completing the welding of one point. After that, the pulley assemblies on the upper telescopic rod and the lower telescopic rod rotate synchronously, and the product is delivered forward by a preset distance for the welding of the next point.

[0041] Compared with the prior art, the present invention has the following advantages:

[0042] 1) The ultrasonic welding tooling in this technical solution can adaptively match the arc-shaped flexible product to be welded, and then can perform automatic feeding according to the preset program, obtaining a precise welding path and regular welding gap, significantly improving the welding stability while enhancing the tightness quality of the welding site.

[0043] 2) In this technical solution, the microprocessor is electrically connected to the first servo motor, the second servo motor, the ultrasonic generator, and the hydraulic cylinder respectively, realizing the fully automatic feeding and welding process, avoiding manual control, and significantly improving the production efficiency. Description of the Drawings

[0044] Figure 1 It is a schematic structural diagram of the ultrasonic welding tooling for arc-shaped flexible products in this technical solution.

[0045] In the figure: 1. Base, 2. Frame body, 3. Upper slide rail, 4. Upper sliding electric cylinder, 5. Lower slide rail, 6. Upper telescopic rod, 7. Lower telescopic rod, 8. Product, 9. Hydraulic cylinder, 10. Hydraulic telescopic rod, 11. Ultrasonic generator, 12. Horn, 13. Welding head, 14. Lower sliding electric cylinder. Specific implementation mode

[0046] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0047] Embodiment

[0048] The ultrasonic welding tooling for arc-surface flexible products in the present invention includes a base 1, a frame body 2, an upper slide rail 3, a lower slide rail 5, an upper sliding electric cylinder 4, a lower sliding electric cylinder 14, an upper telescopic rod 6, a lower telescopic rod 7, a hydraulic cylinder 9, a hydraulic telescopic rod 10, an ultrasonic generator 11, a transducer and a horn 12, see Figure 1 . In this embodiment, the product 8 for ultrasonic welding is an arc-surface flexible plastic product, such as artificial leather, PVC film, plastic heat insulation pad and other products.

[0049] In terms of vertical position adjustment, this ultrasonic welding tooling can adaptively match the arc-surface flexible product to be welded, and then can perform automatic feeding according to a preset program, obtaining a precise welding path and regular welding gap, significantly improving the welding stability while enhancing the tightness quality of the welding site. Among them, the frame body 2 is arranged on the base 1, the upper slide rail 3 is arranged on the frame body 2, the lower slide rail 5 is arranged on the base 1, the upper sliding electric cylinder 4 is arranged on the upper slide rail 3, and the upper sliding electric cylinder 4 can displace along the upper slide rail 3. The lower sliding electric cylinder 14 is arranged on the lower slide rail 5, and the lower sliding electric cylinder 14 can displace along the lower slide rail 3. The upper telescopic rod 6 and the lower telescopic rod 7 are respectively connected to the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14. Pulley assemblies are provided at the opposite ends of the upper telescopic rod 6 and the lower telescopic rod 7, and the product 8 to be welded is clamped between the pulley assemblies on the upper telescopic rod 6 and the lower telescopic rod 7.

[0050] In terms of the ultrasonic welding component, in this embodiment, the ultrasonic generator 11 is arranged on the base 1, the transducer and the horn 12 are connected to the ultrasonic generator 11, a welding head 13 is provided at the end of the horn 12, the welding head 13 is located below the hydraulic telescopic rod 10, and the hydraulic telescopic rod 10 presses down the product 8 until it presses against the welding head 13 to complete the welding of one point. Then, the pulley assemblies on the upper telescopic rod 6 and the lower telescopic rod 7 rotate synchronously to deliver the product 8 forward by a preset distance for the welding of the next point. The hydraulic cylinder 9 is arranged on the frame body 2, and the hydraulic telescopic rod 10 is connected to the hydraulic cylinder 9.

[0051] In terms of horizontal position adjustment, a horizontal working platform is provided on the frame body 2, and the upper sliding rail 3 is provided on the lower surface of the horizontal working platform. The upper end of the upper sliding electric cylinder 4 is movably limited in the upper sliding rail 3, and the upper sliding electric cylinder 4 can perform horizontal position adjustment along the upper sliding rail 3. The lower sliding rail 5 is provided on the upper surface of the base 1, and the lower end of the lower sliding electric cylinder 14 is movably limited in the lower sliding rail 5, and the lower sliding electric cylinder 14 can perform horizontal position adjustment along the lower sliding rail 5. Rack teeth are provided on both the upper sliding rail 3 and the lower sliding rail 5, gears matching the tooth patterns on the rack teeth are provided on both the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14, and a first servo motor drivingly connected to the gears is further provided on the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14. The driving of the gears is realized through the first servo motor, so as to realize the horizontal displacement of the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14 according to instructions. The pulley assembly includes a pulley and a second servo motor drivingly connected to the pulley. The welding tooling further includes a microprocessor;

[0052] In terms of automatic control, the microprocessor is electrically connected to the first servo motor, the second servo motor, the ultrasonic generator 11, and the hydraulic cylinder 9 respectively, realizing a fully automated feeding and welding process, avoiding manual control, and significantly improving production efficiency. The microprocessor is electrically connected to the first servo motor, the second servo motor, the ultrasonic generator 11, and the hydraulic cylinder 9 respectively. The microprocessor issues command signals to the first servo motor and the second servo motor according to a preset program to control the first servo motor and the second servo motor to perform programmed torque output. Specifically in implementation, the electrical connection is a wired connection or a wireless connection. The ultrasonic welding tooling further includes a touch display screen, and the touch display screen is electrically connected to the microprocessor to realize human-machine interaction. Specifically in implementation, the microprocessor is an ARM processor.

[0053] During the specific ultrasonic welding process, the following steps are included:

[0054] S1: Set the feeding program and the ultrasonic welding program according to the arc surface size of the product 8.

[0055] S2: The microprocessor instructs the first servo motor to perform programmed torque output according to the preset feeding program, thereby adjusting the horizontal positions of the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14, and at the same time instructs the upper sliding electric cylinder 4 and the lower sliding electric cylinder 14 to perform thrust output, thereby controlling the elongation amounts of the upper telescopic rod 6 and the lower telescopic rod 7, so that the product 8 to be welded can be clamped between the pulley assemblies on the upper telescopic rod 6 and the lower telescopic rod 7 in a matching manner. During this process, the welding tooling further includes pressure sensors provided on the pulley assemblies. Each pressure sensor can sense the pressure values on each pulley assembly and feedback them to the microprocessor for comparison, so as to realize further pressure adjustment and make the pressure values at each position the same.

[0056] S3: The microprocessor outputs torque programmatically according to the preset ultrasonic welding program instructions to the second servo motor, and instructs the hydraulic cylinder 9 to output pressure programmatically, so that the hydraulic telescopic rod 10 presses down the product 8 until it presses against the welding head 13, completing the welding of one point. After that, the pulley assemblies on the upper telescopic rod 6 and the lower telescopic rod 7 rotate synchronously to deliver the product 8 forward by a preset distance for the welding of the next point.

[0057] The above description of the embodiments is to enable those of ordinary skill in the art to understand and use the invention. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative efforts. Therefore, the present invention is not limited to the above embodiments, and the improvements and modifications made by those skilled in the art according to the disclosure of the present invention without departing from the scope of the present invention should be within the protection scope of the present invention.

Claims

1. An ultrasonic welding tool for curved flexible products, characterized in that: include: Base (1); A frame (2) is arranged on the base (1); An upper slide rail (3) is arranged on the frame (2); A lower sliding rail (5) is arranged on the base (1); An upper sliding electric cylinder (4) is arranged on the upper sliding rail (3), and the upper sliding electric cylinder (4) can be displaced along the upper sliding rail (3); A lower sliding electric cylinder (14) is disposed on the lower sliding rail (5), and the lower sliding electric cylinder (14) can be displaced along the lower sliding rail (5); The upper telescopic rod (6) and the lower telescopic rod (7) are connected to the upper sliding electric cylinder (4) and the lower sliding electric cylinder (14) respectively, and pulley assemblies are provided at opposite ends of the upper telescopic rod (6) and the lower telescopic rod (7), and the product (8) to be welded is clamped between the pulley assemblies on the upper telescopic rod (6) and the lower telescopic rod (7); A hydraulic cylinder (9) is arranged on the frame (2); A hydraulic telescopic rod (10) connected to the hydraulic cylinder (9); An ultrasonic generator (11) is arranged on the base (1); The transducer and the amplitude change rod (12) are connected to the ultrasonic generator (11); a welding head (13) is provided at the end of the amplitude change rod (12); the welding head (13) is located below the hydraulic telescopic rod (10); the hydraulic telescopic rod (10) presses the product (8) downward until it is pressed against the welding head (13) to complete welding at one point; then, the pulley assemblies on the upper telescopic rod (6) and the lower telescopic rod (7) rotate synchronously to deliver the product (8) forward a preset distance to perform welding at the next point; The frame (2) is provided with a horizontal working platform; The upper slide rail (3) is arranged on the lower surface of the horizontal working platform; The upper end of the upper sliding electric cylinder (4) is movable and limited within the upper sliding rail (3); The upper sliding electric cylinder (4) is capable of adjusting the horizontal position along the upper sliding rail (3); The product (8) is a plastic product with a curved and flexible surface.

2. The ultrasonic welding tool for curved flexible products according to claim 1, characterized in that: The lower sliding rail (5) is arranged on the upper surface of the base (1); The lower end of the lower sliding electric cylinder (14) is movable and limited within the lower sliding rail (5); The lower sliding electric cylinder (14) can adjust the horizontal position along the lower sliding rail (5).

3. The ultrasonic welding tool for curved flexible products according to claim 2, characterized in that: The upper slide rail (3) and the lower slide rail (5) are both provided with racks; The upper sliding electric cylinder (4) and the lower sliding electric cylinder (14) are both provided with gears that match the tooth patterns on the rack; The upper sliding electric cylinder (4) and the lower sliding electric cylinder (14) are also provided with a first servo motor which is transmission-connected to the gear.

4. The ultrasonic welding tool for curved flexible products according to claim 3, characterized in that: The pulley assembly comprises a pulley and a second servo motor which is transmission-connected to the pulley.

5. The ultrasonic welding tool for curved flexible products according to claim 4, characterized in that: The welding tool also includes a microprocessor; The microprocessor is electrically connected to the first servo motor, the second servo motor, the ultrasonic generator (11), and the hydraulic cylinder (9) respectively; The microprocessor sends a command signal to the first servo motor and the second servo motor according to a preset program to control the first servo motor and the second servo motor to perform programmed torque output.

6. The ultrasonic welding tool for curved flexible products according to claim 5, characterized in that: The electrical connection is a wired connection or a wireless connection; The ultrasonic welding tool also includes a touch display screen, which is electrically connected to the microprocessor to achieve human-computer interaction.

7. The ultrasonic welding tool for curved flexible products according to claim 6, characterized in that: The microprocessor is an ARM processor.

8. A welding method for curved flexible products, characterized in that: The method is implemented by using the ultrasonic welding tool as described in any one of claims 1 to 7. The following steps are involved: S1: Setting the feeding program and ultrasonic welding program according to the arc surface size of the product (8); S2: The microprocessor instructs the first servo motor to perform programmed torque output according to a preset feeding program, thereby adjusting the horizontal positions of the upper sliding electric cylinder (4) and the lower sliding electric cylinder (14), and at the same time instructs the upper sliding electric cylinder (4) and the lower sliding electric cylinder (14) to output thrust, thereby controlling the elongation of the upper telescopic rod (6) and the lower telescopic rod (7), so that the product (8) to be welded can be matched and clamped between the pulley assemblies on the upper telescopic rod (6) and the lower telescopic rod (7); S3: The microprocessor instructs the second servo motor to perform programmed torque output according to a preset ultrasonic welding program, and instructs the hydraulic cylinder (9) to perform programmed pressure output, so that the hydraulic telescopic rod (10) presses the product (8) downward until it presses against the welding head (13), completing the welding of one point, and then the pulley assemblies on the upper telescopic rod (6) and the lower telescopic rod (7) rotate synchronously, delivering the product (8) forward a preset distance, and performing welding at the next point.

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