An ultrasonic wave cutter on-line cleaning strengthening system and method, and an ultrasonic wedge bonding machine

Abstract

The application discloses an ultrasonic tool on-line cleaning and strengthening system, which comprises a laser cleaning and strengthening device and a tool detection device. The laser cleaning and strengthening device comprises a laser head connected to a laser generator through an optical fiber. The laser head irradiates laser to the ultrasonic tool to be cleaned to perform laser cleaning and laser impact strengthening. The tool detection device is connected to the laser generator in signal and detects the surface cleaning state of the working area of the ultrasonic tool to be cleaned. When the surface cleaning state exceeds a preset range, the tool detection device sends a signal to instruct the laser cleaning and strengthening device to perform laser cleaning. The tool head is periodically impacted and strengthened by using the laser impact characteristics. The system can clean and strengthen the ultrasonic tool on-line and non-contact, improves the production efficiency and quality of ultrasonic machining, and prolongs the tool life. The application further provides an ultrasonic tool on-line cleaning and strengthening method and an ultrasonic wedge bonding machine.

Description

Technical Field

[0001] This invention belongs to the field of ultrasonic cutting and welding, specifically relating to an online cleaning and strengthening system and method for ultrasonic cutting tools, and an ultrasonic wedge welding machine. Background Technology

[0002] After continuous operation, ultrasonic cutting tools often develop adhesive residues of the processed metal at their tips. For example, aluminum accumulates at the tip of the wedge in an aluminum wedge welding machine. These metal residues, when accumulated to a certain extent, are prone to detaching during continuous ultrasonic cutting tool operation. This poses a risk of product damage and affects the energy transfer efficiency of the ultrasonic wedge, impacting processing quality. Currently, conventional processes require periodic disassembly and offline cleaning of ultrasonic cutting tools followed by reassembly. This leads to production line downtime, affecting efficiency, and may introduce assembly errors during disassembly and installation, negatively impacting production stability. Therefore, providing an online cleaning and strengthening system for ultrasonic cutting tools is of significant importance for improving the efficiency and quality of continuous ultrasonic processing production. Summary of the Invention

[0003] The purpose of this invention is to provide an online ultrasonic tool cleaning and strengthening system for online cleaning and maintenance of ultrasonic tools. This invention also provides an online ultrasonic tool cleaning method and an ultrasonic wedge welding machine.

[0004] According to one embodiment of the present invention, an online cleaning and strengthening system for ultrasonic cutting tools is provided, comprising a laser cleaning and strengthening device and a cutting tool detection device; wherein, the laser cleaning and strengthening device includes a laser generator, an optical fiber, and a laser head, the laser generator generates laser light, the optical fiber connects to the laser generator and guides the laser light to one or more laser heads, the laser heads irradiate the ultrasonic cutting tool to be cleaned with the laser light; the cutting tool detection device is signal-connected to the laser cleaning and strengthening device, the cutting tool detection device detects the cleanliness status of the working area of ​​the ultrasonic cutting tool to be cleaned, and when the cleanliness status of the ultrasonic cutting tool to be cleaned exceeds a preset range, the cutting tool detection device sends a signal to instruct the laser cleaning and strengthening device to perform laser cleaning and strengthening.

[0005] This system can use a laser cleaning and strengthening device to clean ultrasonic tools online, replacing physical grinding or chemical immersion. It eliminates the need to disassemble the ultrasonic tools, avoiding the time consumption caused by offline cleaning and the assembly errors caused by reinstallation after cleaning. While vaporizing and cleaning the metal adhesion in the working area, the laser pulse can also strengthen the surface of the working area through laser impact, thereby extending the service life of the ultrasonic tools.

[0006] Furthermore, in some embodiments, the laser energy output by the laser head is 5J-9J, and the pulse width is 10ns-20ns.

[0007] Furthermore, in some embodiments, the tool detection device includes a visual recognition device that captures an image of the working area of ​​the ultrasonic tool to be cleaned, wherein the cleaning state is configured as an image of the residual metal adhesion state of the working area.

[0008] Furthermore, in some embodiments, the visual recognition device is equipped with an ultrasonic tool visual recognition model, which is trained using image samples of different residual metal adhesion states in the working area and can automatically identify the residual metal adhesion state in the working area.

[0009] Furthermore, in some embodiments, the tool detection device further includes an unloaded detection device, which detects the unloaded working state of the ultrasonic tool to be cleaned. The method for detecting the cleaning state further includes detecting changes in the unloaded working state caused by residual metal adhesion in the working area.

[0010] Furthermore, in some embodiments, the no-load operating state includes one or more of the resonant frequency, resonant current, and impedance measured by exciting the transducer of the ultrasonic tool to be cleaned with an no-load test voltage in the no-load state.

[0011] Furthermore, in some embodiments, the no-load test voltage is configured to be 10%-30% of the normal operating voltage.

[0012] Furthermore, in some embodiments, the tool detection device further includes a post-processing visual recognition device, which performs visual recognition on the product state obtained by the ultrasonic tool to be cleaned. When the product state exceeds a preset range, the tool detection device sends a signal to instruct the laser cleaning and strengthening device to perform laser cleaning and strengthening.

[0013] According to another embodiment of the present invention, an online ultrasonic tool cleaning method is provided. This method employs the online ultrasonic tool cleaning and enhancement system provided in any of the foregoing embodiments and includes the following steps:

[0014] Step a): Use the tool detection device to detect the cleaning status of the working area of ​​the ultrasonic tool to be cleaned. If the cleaning status does not exceed the preset range, proceed to step b); if the cleaning status exceeds the preset range, use the laser cleaning enhancement device to perform laser cleaning on the working area until the cleaning status does not exceed the preset range, then proceed to step b).

[0015] Step b): Perform ultrasonic processing and return to step a) after the operation cycle is completed.

[0016] Furthermore, in some embodiments, step a) further includes a counting step and a counting verification step. When the cleaning state exceeds a preset range, the count is increased by 1, and the count is checked before laser cleaning to see if it exceeds a given threshold. When the count exceeds the given threshold, laser cleaning is stopped, the ultrasonic tool to be cleaned is replaced, and the count is restarted.

[0017] Furthermore, in some embodiments, step a) further includes a step of laser strengthening of the working area when performing laser cleaning on the working area.

[0018] According to another embodiment of the present invention, a wedge welding machine is provided, including an ultrasonic component and a wedge, the ultrasonic component driving the wedge to perform ultrasonic welding, and further including an online cleaning system for cleaning the wedge, the online cleaning system employing the ultrasonic tool online cleaning and strengthening system provided in any of the foregoing embodiments. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the ultrasonic wedge welding machine structure in one embodiment;

[0020] Figures 2a to 2d This is a photograph showing the gradual increase in aluminum adhesion in the working area of ​​the cleaver in one embodiment;

[0021] Figure 3a This is a photograph showing aluminum adhesion in the working area of ​​the cleaver in one embodiment;

[0022] Figure 3b This is a photograph of the working area of ​​the cleaver after laser cleaning in one embodiment;

[0023] Figure 4a for Figure 3a The corresponding no-load test impedance curve;

[0024] Figure 4b for Figure 3b The corresponding no-load test impedance curve;

[0025] Figure 5 This is a photograph of a sample welded by a wedge welding machine in one embodiment.

[0026] Meaning of the reference numerals in the attached diagram: 1-cleaving blade; 2-ultrasonic component; 3-laser generator; 4-optical fiber; 5-laser head; 6-aluminum adhesion; 7-welding defect.

[0027] The purpose of the above-described drawings is to provide a detailed description of the present invention so that those skilled in the art can understand the technical concept of the invention, and is not intended to limit the invention. For the sake of brevity, the above-described drawings only schematically depict the structures related to the technical features of the present invention, and do not depict the complete structure and all details strictly according to actual scale. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0029] The term "embodiment" as used herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment herein. The phrase appearing in various places in the specification does not necessarily refer to the same embodiment, nor is it limited to mutually exclusive, independent, or alternative embodiments. Those skilled in the art will understand that the embodiments herein can be combined with other embodiments without causing structural conflicts.

[0030] In this description, unless otherwise expressly specified and limited, the technical terms "installation," "connection," "joining," etc., should be interpreted broadly, referring to movable connections, fixed connections, or integration. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this application based on the specific circumstances.

[0031] In this description, terms such as "upper," "lower," "left," "right," "lateral," "longitudinal," "height," "length," and "width," which indicate orientation or positional relationships, are intended to accurately describe the embodiments and simplify the description, rather than limiting the parts or structures involved to have a specific orientation, or to be installed or operated in a specific orientation, and should not be construed as limiting the embodiments in this document.

[0032] In this description, terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating relative importance or limiting the number, specific order, or primary / secondary relationship of the described technical features. In this description, "multiple" means at least two.

[0033] Ultrasonic tools used for metalworking, such as welding or cutting, transmit high-frequency mechanical vibrations to the metal to be processed via ultrasonic cutters to achieve welding or cutting. Ultrasonic cutters are typically made of high-melting-point metals such as tungsten alloys or tungsten steel, while the metals being processed are usually alloys with lower melting points, such as aluminum. During processing, the part of the ultrasonic cutter in contact with the metal is prone to adhesion, causing some of the processed metal to adhere to the working area of ​​the ultrasonic cutter. This affects the efficiency of ultrasonic energy transmission, and the accumulated adhered metal may randomly detach as the ultrasonic cutter works, posing a risk of damaging the processed parts.

[0034] Currently, offline cleaning is commonly used for adhered metals. For example, for aluminum buildup on ultrasonic cutting tools caused by aluminum processing, the tools need to be removed and immersed in a 20% sodium hydroxide solution for ultrasonic cleaning, followed by rinsing and drying. Finally, the tools are reinstalled in the processing equipment and calibrated. This disassembly and reinstallation process is time-consuming, the production line must be stopped during tool cleaning, and assembly errors are unavoidable during reinstallation. Offline tool cleaning is also detrimental to the stability of the production line.

[0035] To address the aforementioned problems, one embodiment of the present invention provides an online ultrasonic tool cleaning and strengthening system, comprising a laser cleaning and strengthening device and a tool detection device. The laser cleaning and strengthening device includes a laser generator and a laser head connected via an optical fiber. The laser generator produces laser light, which is transmitted to the laser head via the optical fiber. The laser head irradiates the ultrasonic tool to be cleaned, utilizing the laser energy to vaporize the metal adhering to the tool, thus achieving laser cleaning. Simultaneously, the laser pulse can strengthen the working area. In different embodiments, the laser generator can be connected to one or more laser heads via an optical fiber. In a preferred embodiment, the laser head outputs laser energy of 5J-9J, a pulse width of 10ns-20ns, and is capable of outputting at least three consecutive laser pulses.

[0036] In a preferred embodiment, the tool detection device includes a visual recognition device. This device can capture images of the working area of ​​the ultrasonic tool to be cleaned and identify the adhesion of residual metal in the working area. Based on the adhesion of the residual metal, it determines whether laser cleaning is required. The visual recognition device may be equipped with a visual recognition model, which is trained based on preset image samples of the residual metal adhesion state in the working area. This model can automatically identify the residual metal adhesion state in the working area and determine whether laser cleaning is required. In a further preferred embodiment, the tool detection device also includes an unloaded detection device. This device detects the unloaded working state of the ultrasonic tool to be cleaned, such as the resonant frequency, resonant current, and impedance under unloaded test voltage excitation, and determines whether laser cleaning is required based on the changes in the unloaded working state caused by the adhesion of residual metal in the working area. In a further preferred embodiment, the unloaded test voltage is 10%-30% of the normal operating voltage.

[0037] In some embodiments, the ultrasonic tool online cleaning and strengthening system is used in ultrasonic wedge welding machines.

[0038] In a preferred embodiment, the ultrasonic wedge welding machine has the following structure: Figure 1 As shown, in operation, the ultrasonic component 2 drives the cutting tool 1 to perform aluminum welding, wherein the cutting tool 1 is made of high-melting-point tungsten alloy. With the continuous operation of the cutting tool 1, as... Figures 2a to 2dAs shown, the amount of aluminum adhering to the weld 6 on the working area of ​​the cleaver 1 gradually increases, affecting the transmission of ultrasonic energy and the welding effect. Excessive aluminum adhering to the weld 6 will also fall off under high-frequency vibration, damaging the welded workpiece and causing it to be scrapped.

[0039] Therefore, the ultrasonic wedge welding machine is equipped with an online ultrasonic cleaning system, which includes a laser generator 3 and a laser head 5. The laser head 5 is connected to the laser generator 3 via an optical fiber 4. The laser generator 3 generates laser pulses, which are transmitted to the laser head 5 via the optical fiber 4 to irradiate the wedge 1 for laser cleaning. In a preferred embodiment, the energy of a single laser pulse is 5J-9J, and the pulse width is 10ns-20ns. When the laser spot irradiates the working area of ​​the wedge 1, the aluminum adhesion 6 will vaporize under the action of the high-energy laser pulse, thus cleaning the working area of ​​the wedge 1.

[0040] The ultrasonic online cleaning system also includes a tool detection device (not shown), which includes a vision recognition device. The vision recognition device comprises an industrial camera and a processor equipped with a tool vision recognition model. During the welding operation, after each welding cycle, the industrial camera captures an image of the working area of ​​the cutting tool 1, and the tool vision recognition model processes and recognizes the image to automatically determine whether laser cleaning is required. In a preferred embodiment, the tool vision recognition model is based on an artificial intelligence algorithm and is trained using image samples of the working area of ​​the cutting tool 1 with manually labeled tags indicating whether laser cleaning is required. Specifically, when establishing image samples, the cutting tool 1 can be used for continuous welding operations, and images of the working area at different stages can be captured. The images of the working area are then manually labeled according to the welding quality. The training of the tool vision recognition model can be pre-loaded during the manufacturing process of the tool detection device, or it can be completed after the tool detection device is deployed on the production line using data accumulated during production. In a preferred embodiment, the tool vision recognition model is pre-trained using multiple different models and specifications of cutting tools 1 to improve compatibility. In some embodiments, the images of the working area of ​​the cutting tool 1 can also be monitored manually to determine whether laser cleaning is required.

[0041] In a preferred embodiment, the tool detection device further includes an unloaded detection device, which is connected to the transducer signal in the ultrasonic component 2 and can detect changes in the working state of the cutting tool 1 under unloaded working conditions. During the unloaded test, the transducer is excited at 10%-30% of the normal operating excitation voltage to detect parameters such as resonant frequency, resonant current, or impedance. These parameters are compared with standard data under conditions without aluminum adhesion to determine the parameter changes caused by aluminum adhesion. Figure 3a As shown, when a large amount of aluminum adheres to the working area of ​​the cleaver 1, the impedance curve during the no-load test is as follows: Figure 4aAs shown, the impedance increased significantly in the initial stage of the test. However, as the ultrasonic vibration was excited, the bonding force between the aluminum adhesion and the cutting tool 1 weakened, reducing its influence on the impedance, and the impedance tended to decrease again. After laser cleaning of the cutting tool 1 to remove the aluminum adhesion 6, as shown... Figure 3b As shown, the no-load test yielded the following results: Figure 4b The impedance curve shown indicates that after the excitation begins and reaches its peak, the impedance remains essentially unchanged. Setting a threshold for the no-load detection device allows for instructing laser cleaning to be initiated when the measured data exceeds the threshold.

[0042] In a preferred embodiment, the tool inspection device further includes a post-weld inspection device as a subsequent visual recognition device. The post-weld inspection device photographs and performs visual recognition on the product welded by the cleaver 1, such as... Figure 5 As shown, when welding defect 7 (including indentation, roughness, and significant burrs) occurs, the tool inspection device can issue a signal to initiate laser cleaning. The visual recognition process of the post-weld inspection device can be performed with manual intervention or using a trained visual recognition model.

[0043] In different embodiments, the control logic of the no-load detection device, the visual recognition device, and the downstream visual recognition device for laser cleaning can be an "AND" relationship or an "OR" relationship.

[0044] In a preferred embodiment, the ultrasonic wedge welding machine is provided with a working station and a cleaning station. At the working station, the wedge 1 performs welding operations on the workpiece to be processed. When the tool detection device detects that the wedge 1 needs to be cleaned, the drive system moves the wedge 1 to the cleaning station. At the cleaning station, the laser head 5 passes through a preset angle to irradiate the working area of ​​the wedge 1. In some embodiments, it can also swing or scan to fully clean the working area of ​​the wedge 1.

[0045] While removing aluminum adhesion 6 using laser cleaning, the working area of ​​the cleaver 1 is subjected to laser shock peening using the energy of the laser pulse. The surface of the working area absorbs the laser energy and forms a rapidly expanding plasma near the surface. When the pressure of the plasma exceeds the elastic limit of the metal material, the metal material undergoes dynamic plastic deformation, resulting in grain refinement and improved fatigue performance and corrosion resistance. Three shocks are performed with an energy of 5J-9J and a pulse width of 10ns-20ns, which significantly improves the microhardness of the working area of ​​the cleaver 1 while removing aluminum adhesion 6. As the service life of the cleaver 1 increases, the surface hardened layer formed by laser shock peening gradually wears off. When laser cleaning is performed again, laser shock peening can be performed again. Since the surface hardened layer has already been worn away, laser shock peening will not cause surface defects such as crack initiation.

[0046] Utilize Figure 1The process of welding and online cleaning using the wedge welding machine shown is as follows:

[0047] Input the work instructions to the wedge welding machine and repeat the welding operation for multiple cycles.

[0048] Before the welding cycle begins, the working area of ​​the cutting tool 1 is first inspected using a tool inspection device. A visual recognition device captures and identifies the surface condition of the working area, and a no-load test voltage is applied to measure the resonant frequency, resonant current, and impedance. If the visual recognition model determines that the aluminum adhesion in the working area of ​​the cutting tool 1 does not meet the cleaning standard or the parameters measured by the no-load test do not exceed the threshold, the cutting tool 1 performs the welding operation normally. Otherwise, the cutting tool 1 is instructed to move to the cleaning station, where the laser head 5 emits a laser to perform laser cleaning and laser shock strengthening on the working area of ​​the cutting tool 1. After the cutting tool 1 performs the welding operation, the post-weld inspection device inspects the welding quality. When the post-weld inspection device determines through visual recognition that the welding quality has defects caused by aluminum adhesion, the tool inspection device also issues an instruction to move the cutting tool 1 to the cleaning station for laser cleaning and strengthening.

[0049] In a preferred embodiment, the tool detection device has a built-in counting system. Before laser cleaning of the cutting tool 1, the count is incremented by 1 and compared with a preset scrap threshold. If the count reaches the scrap threshold, the laser cleaning process is stopped, and an alarm is issued indicating that the cutting tool 1 needs to be scrapped and replaced. If the count does not reach the scrap threshold, the laser cleaning process proceeds normally. In some embodiments, the scrap threshold can be set to 6-10. In some embodiments, a visual recognition device can also be used to perform contour detection on the cutting tool 1. When the contour detection exceeds a predetermined limit, an alarm is also issued indicating that the cutting tool 1 needs to be scrapped and replaced. The count is reset after the cutting tool 1 is replaced.

[0050] In some preferred embodiments, multiple wedge welding machines can be connected to the same ultrasonic tool online cleaning and strengthening system. The laser generated by the laser generator 3 is directed to different laser heads 5 by the branched optical fiber 4. Each laser head 5 is equipped with a control switch to perform laser cleaning and laser shock strengthening on different equipment, thereby improving cleaning efficiency and saving equipment space.

[0051] In a preferred embodiment, the welding operation and laser cleaning process of the wedge welding machine can be automated through preset program control. Online laser cleaning is automatically performed during the welding operation, which improves production efficiency, saves labor costs, and reduces the safety hazards caused by manual operation of the laser.

[0052] The ultrasonic tool online cleaning and strengthening system provided in the above embodiments can use laser cleaning to clean ultrasonic tools online. The cleaning process is highly efficient, precise, and involves no physical contact. It does not generate toxic or harmful waste, is energy-saving and environmentally friendly, and can improve the level of automated production in ultrasonic welding. While removing metal adhesion, it can also strengthen the surface of ultrasonic tools and extend their service life.

[0053] The purpose of the above embodiments is to provide a further detailed description of the present invention in conjunction with the accompanying drawings, so that those skilled in the art can understand the technical concept of the present invention. Within the scope of the present invention, optimization or equivalent substitution of the involved part structures or method steps, as well as combination of implementation methods in different embodiments without causing structural and principle conflicts, all fall within the protection scope of the present invention.

Claims

1. An ultrasonic tool in-line cleaning enhancement system, comprising: This includes a laser cleaning and strengthening device and a tool inspection device; among which, The laser cleaning enhancement device includes a laser generator, an optical fiber, and a laser head. The laser generator generates laser light, and the optical fiber connects to the laser generator and guides the laser light to one or more laser heads. The laser heads irradiate the ultrasonic blade to be cleaned with the laser light. The tool detection device is signal-connected to the laser cleaning and strengthening device. The tool detection device detects the cleanliness of the working area of ​​the ultrasonic tool to be cleaned. When the cleanliness of the ultrasonic tool to be cleaned exceeds a preset range, the tool detection device sends a signal to instruct the laser cleaning and strengthening device to perform laser cleaning and strengthening. The tool detection device includes a vision recognition device, which captures an image of the working area of ​​the ultrasonic tool to be cleaned. The cleaning state is configured as an image of the residual metal adhesion state of the working area. The vision recognition device is equipped with an ultrasonic tool vision recognition model, which is trained using preset image samples of different residual metal adhesion states of the working area and can automatically identify the residual metal adhesion state of the working area. The tool detection device also includes an unloaded detection device, which detects the unloaded working state of the ultrasonic tool to be cleaned. The method for detecting the cleaning state also includes detecting changes in the unloaded working state caused by residual metal adhesion in the working area.

2. The ultrasonic tool in-line cleaning enhancement system of claim 1, wherein, The laser head outputs a laser energy of 5J-9J and a pulse width of 10ns-20ns.

3. The ultrasonic tool in-line cleaning enhancement system of claim 1, wherein, The no-load working state includes one or more of the resonant frequency, resonant current, and impedance measured when the ultrasonic tool to be cleaned is excited by the transducer of the ultrasonic tool to be cleaned under no-load conditions with an no-load test voltage.

4. The ultrasonic tool in-line cleaning enhancement system of claim 3, wherein, The no-load test voltage is configured to be 10%-30% of the normal operating voltage.

5. The ultrasonic tool online cleaning and strengthening system according to claim 1, characterized in that, The tool detection device also includes a post-processing visual recognition device, which visually recognizes the state of the product processed by the ultrasonic tool to be cleaned. When the product state exceeds a preset range, the tool detection device sends a signal to instruct the laser cleaning and strengthening device to perform laser cleaning and strengthening.

6. A method for online cleaning and strengthening of ultrasonic cutting tools, characterized in that, The ultrasonic tool online cleaning and strengthening system as described in any one of claims 1 to 5 includes the following steps: Step a): Use the tool detection device to detect the cleanliness of the working area of ​​the ultrasonic tool to be cleaned. If the cleanliness is within a preset range, proceed to step b). If the cleanliness exceeds the preset range, use the laser cleaning enhancement device to perform laser cleaning and enhancement on the working area until the cleanliness is within the preset range, then proceed to step b). Step b): Perform ultrasonic processing and return to step a) after the operation cycle is completed.

7. The ultrasonic tool online cleaning and strengthening method according to claim 6, characterized in that, Step a) further includes a counting step and a counting verification step. When the cleaning state exceeds the preset range, the count is increased by 1. Before laser cleaning, the count is checked to see if it exceeds a given threshold. When the count exceeds the given threshold, laser cleaning is stopped, the ultrasonic tool to be cleaned is replaced, and the count is restarted.

8. A wedge welding machine, comprising an ultrasonic component and a wedge blade, wherein the ultrasonic component drives the wedge blade to perform ultrasonic welding, characterized in that, The wedge welding machine further includes an online cleaning and strengthening system for cleaning and strengthening the wedge. The online cleaning and strengthening system employs an ultrasonic tool online cleaning and strengthening system as described in any one of claims 1 to 5. The wedge welding machine includes a working station and a cleaning station. The wedge can move between the working station and the cleaning station. At the working station, the wedge is subjected to ultrasonic welding.

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