Ultrasonic welding transducer switching control box cascade system and method

Abstract

The invention provides an ultrasonic welding transducer switching control box cascading system and method. The system comprises an ultrasonic generator and a plurality of cascaded transducer switching control boxes, and the transducer switching control boxes are connected with a plurality of transducers; the first input end of the cascaded first transducer switching control box is connected with the first output end of the ultrasonic generator, and the first input ends of the other cascaded transducer switching control boxes are connected with the second output end of the previous transducer switching control box; the first output end of the ultrasonic generator and the second output end of each transducer switching control box output time sequence control signals; the sequential control signal is provided for the transducer switching control box to complete the numbering of the transducers; the second input end of the transducer switching control box is connected with the second output end of the ultrasonic generator; the second output end of the ultrasonic generator outputs a communication signal; and the communication signal is used for the transducer switching control box to complete the switching of the transducers with specified numbers. The system is more flexible, efficient and easy to manage.

Description

Technical Field

[0001] The invention belongs to the technical field of ultrasonic welding machines, and in particular relates to an ultrasonic welding transducer switching control box cascade system and method. Background Art

[0002] In the field of automobile door panel puncture welding, due to the large number of welding points and different welding molds, in order to reduce costs, it is usually necessary to use an ultrasonic generator to control multiple transducers to work in a predetermined sequence. In order to achieve the switching control of multiple transducers, the industry method is to use a separately designed transducer switching control box to switch the transducers, and the ultrasonic generator and the transducer switching control box are controlled by a communication protocol or a coding composed of multiple lines.

[0003] In the prior art, a single transducer switching control box can usually only control a fixed limited number of transducers (such as 4 / 8 / 16), so that users can choose transducer switching control boxes with different expansion numbers according to their needs to expand the transducer. If you want to design a separate transducer switching control box with different numbers of expansion ports for an ultrasonic generator, the transducer switching control box cannot be universal, increasing research and development and inventory costs. When you need to control 12 transducers, you may need to purchase a transducer switching control box that controls 16 switching boxes. The system is likely to have multiple generators and transducer switching control boxes, which leads to a larger installation space, higher costs, and serious waste of resources. If a transducer switching control box that controls 8 transducers is used, when the workload expansion requires an increase in the number of transducers, it is necessary to purchase and replace the model of the transducer switching control box or add a new generator and change the PLC controller, which is inconvenient to expand and may lead to insufficient installation space. If a single generator needs to drive more than 16 transducers, it is difficult to find a transducer switching control box that meets the requirements on the market, and the user is forced to increase the number of ultrasonic generators, which are costly, bulky, and heavy. Summary of the invention

[0004] In view of the defects in the prior art, the present invention provides an ultrasonic welding transducer switching control box cascade system and method, which is easy to expand and has higher flexibility.

[0005] An ultrasonic welding transducer switching control box cascade system includes an ultrasonic generator and a plurality of cascaded transducer switching control boxes, wherein a plurality of first output ends of each transducer switching control box are connected to a plurality of transducers;

[0006] The first input end of the first transducer switching control box of the cascade is connected to the first output end of the ultrasonic generator, and the first input ends of other transducer switching control boxes of the cascade are connected to the second output end of the previous transducer switching control box; the first output end of the ultrasonic generator and the second output end of each transducer switching control box output a timing control signal; the timing control signal is used for the transducer switching control box to complete the numbering of the transducers;

[0007] The second input end of the transducer switching control box is connected to the second output end of the ultrasonic generator; the second output end of the ultrasonic generator outputs a communication signal; the communication signal is used for the transducer switching control box to complete the switching of the transducer with a specified number.

[0008] Furthermore, the transducer switching control box includes: a communication module, a control module and a switching circuit;

[0009] Communication module: connected to the input end of the control module, the first input end and the second input end of the transducer switching control box; the communication module is used for bidirectional data exchange with the ultrasonic generator;

[0010] The output end of the control module is connected to the switching circuit; the control module is used to complete the numbering of the transducers and generate the switching control instructions; the switching control instructions are generated according to the communication signal;

[0011] The switching circuit includes multiple cascaded relays; the first contact of the first cascaded relay receives a high-voltage transducer drive signal, the first contacts of other cascaded relays are connected to the second contacts of the previous relay, and the second contact of the last cascaded relay is connected to the first output end of the transducer switching control box; the control end of each relay receives a switching control instruction.

[0012] Furthermore, the transducer switching control box also includes:

[0013] Display module: connected to the control module; the display module is used to display the communication connection status of the transducer switching control box and the working status of the relay.

[0014] Furthermore, the switching control instruction is used to control the first contact and the second contact of the relay to be disconnected or connected, thereby realizing the switching of the working state of the transducer.

[0015] In a second aspect, a method for cascading an ultrasonic welding transducer switching control box is provided, which is run on the above system; the method comprises:

[0016] When the system is powered on, the ultrasonic generator sends a timing control signal;

[0017] When the transducer switching control box receives the timing control signal, it calculates the time difference between the timing control signal reception time and the system power-on time; determines the control box number according to the time difference, and transmits the timing control signal to the next transducer switching control box after delaying according to the time threshold;

[0018] The transducer switching control box determines the transducer number of the transducer according to the control box number;

[0019] The ultrasonic generator sends a communication signal;

[0020] When the transducer switching control box receives the communication signal, it parses and obtains the transducer number in the communication signal, which is defined as the target number;

[0021] When the transducer switching control box detects that the transducer number of the connected transducer includes the target number, the transducer corresponding to the target number is switched to start working.

[0022] Furthermore, the control box number is a multiple of the time difference and the time threshold + 1.

[0023] Furthermore, the transducer numbers of the transducers connected to the transducer switching control box are: total number of transducers*(control box number-1)+1~total number of transducers*control box number; the total number of transducers is the number of transducers connected to the transducer switching control box.

[0024] Furthermore, switching the transducer corresponding to the target number to start working specifically includes:

[0025] generating a switching control instruction;

[0026] The switching control instruction is sent to the relay connected to the transducer corresponding to the target number, and the relay is controlled to close, so that the transducer corresponding to the target number is connected to the ultrasonic generator and receives the high-voltage transducer driving signal output by the ultrasonic generator.

[0027] Furthermore, after the system is powered on, it also includes:

[0028] The transducer switching control box establishes a communication connection with the ultrasonic generator according to the Modbus address of the ultrasonic generator.

[0029] Furthermore, after the transducer corresponding to the switching target number starts to work, the method further includes:

[0030] The transducer switching control box corresponding to the target number generates a Modbus response message and returns it to the ultrasonic generator;

[0031] The ultrasonic generator determines whether the timing control signal is correctly executed according to the received Modbus response information, and performs shutdown error, reminder or ignore operation.

[0032] It can be seen from the above technical solution that the ultrasonic welding transducer switching control box cascade system and method provided by the present invention has the following advantages:

[0033] 1) Significantly improved scalability: The transducer switching control box adopts a cascade design, allowing multiple transducer switching control boxes to be used in series to achieve unlimited expansion, breaking the limitation of traditional fixed number transducer control. Users can flexibly increase the number of transducer switching control boxes according to actual needs without replacing the entire system, which greatly improves scalability and ease of use.

[0034] 2) Automatic numbering mechanism simplifies configuration; innovative use of timing control signals to achieve automatic numbering of transducer switching control boxes and transducers eliminates the need for manual configuration. When adding a new transducer switching control box, simply cascade the new transducer switching control box after the last transducer switching control box, so that the number is automatically assigned at the next power-on, greatly simplifying the system expansion and maintenance process and reducing the difficulty of development.

[0035] 3) Unified communication protocol improves compatibility; all transducer switching control boxes use the same Modbus address to connect to the ultrasonic generator, simplifying the complexity of the communication protocol. Unified communication method improves compatibility and facilitates future upgrades and maintenance.

[0036] 4) Efficient command processing mechanism: The communication signal sent by the ultrasonic generator can be received by all transducer switching control boxes at the same time, but only the relevant transducer switching control box responds, which improves the response speed and efficiency, reduces unnecessary communication overhead, and optimizes system performance.

[0037] 5) Significant cost-effectiveness; there is no need to design multiple transducer switching control boxes for different numbers of transducers, which reduces R&D costs. The use of standardized transducer switching control boxes can reduce inventory types and inventory costs. Users can gradually expand the system according to their needs, avoiding a one-time large investment.

[0038] 6) Easy operation and maintenance: Automatic numbering and unified communication protocols greatly simplify the configuration and maintenance process. The standardized transducer switching control box facilitates troubleshooting and replacement, improving maintainability.

[0039] 7) Strong adaptability; suitable for various application scenarios that require multiple transducers to switch, such as automobile door panel puncture welding and other fields. Flexible expansion capabilities can easily adapt to production needs of different scales.

[0040] 8) Improve production efficiency; fast transducer switching and efficient communication mechanisms help improve the overall efficiency of the production line. Scalability allows the production line to be quickly adjusted according to demand, reducing downtime.

[0041] 9) Save space; compared with the traditional solution that requires multiple transducer switching control boxes of different models, the use of a standardized transducer switching control box can make more effective use of the equipment installation space.

[0042] 10) Future upgrade potential: unified communication protocol and modular design facilitate future functional expansion and performance improvement. Flexibility makes it easy to adapt to new transducers or new application requirements that may appear in the future. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the specific embodiments or the description of the prior art. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn according to the actual scale.

[0044] Figure 1 A module block diagram of an ultrasonic welding transducer switching control box cascade system provided in an embodiment.

[0045] Figure 2 A module block diagram of a transducer switching control box provided in an embodiment.

[0046] Figure 3 A circuit diagram of a single transducer switching circuit provided for an embodiment.

[0047] Figure 4 A flow chart of a cascading method for an ultrasonic welding transducer switching control box provided in an embodiment.

[0048] Figure 5 A sequence diagram of the ultrasonic welding transducer switching control box cascading method provided in an embodiment. DETAILED DESCRIPTION

[0049] The embodiments of the technical solution of the present invention will be described in detail below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore only used as examples, and the protection scope of the present invention cannot be limited thereto. It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should be the common meanings understood by those skilled in the art to which the present invention belongs.

[0050] It should be understood that when used in this specification and the appended claims, the terms "include" and "comprises" indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0051] It should also be understood that the terms used in this specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. As used in the specification of the present invention and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0052] As used in this specification and the appended claims, the term "if" may be interpreted as "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrases "if it is determined" or "if [described condition or event] is detected" may be interpreted as meaning "upon determination" or "in response to determining" or "upon detection of [described condition or event]" or "in response to detecting [described condition or event]," depending on the context.

[0053] Example:

[0054] An ultrasonic welding transducer switching control box cascade system includes an ultrasonic generator and a plurality of cascaded transducer switching control boxes, wherein a plurality of first output ends of each transducer switching control box are connected to a plurality of transducers;

[0055] The first input end of the first transducer switching control box of the cascade is connected to the first output end of the ultrasonic generator, and the first input ends of other transducer switching control boxes of the cascade are connected to the second output end of the previous transducer switching control box; the first output end of the ultrasonic generator and the second output end of each transducer switching control box output a timing control signal; the timing control signal is used for the transducer switching control box to complete the numbering of the transducers;

[0056] The second input end of the transducer switching control box is connected to the second output end of the ultrasonic generator; the second output end of the ultrasonic generator outputs a communication signal; the communication signal is used for the transducer switching control box to complete the switching of the transducer with a specified number.

[0057] In this embodiment, generally, the transducer switching control box can be connected to 4 / 8 / 16 transducers. This embodiment is described by connecting the transducer switching control box to 4 transducers. The ultrasonic welding transducer switching control box cascade system includes an ultrasonic generator, N cascaded transducer switching control boxes, each transducer switching control box is connected to 4 transducers through 4 first output terminals, the first input terminal provides a signal source for the 4 first output terminals, and uses a high-voltage coaxial connector, and the withstand voltage is usually required to be greater than 3000Vac rms. See Figure 1, where the first transducer switching control box is connected to the ultrasonic generator and receives the timing control signal, and the non-first transducer switching control box in the cascade is connected to the previous transducer switching control box and receives the timing control signal forwarded by the previous transducer switching control box. After receiving the timing control signal, the transducer switching control box completes the numbering of the transducers. For example, the four transducers connected to the first transducer switching control box are coded as 1, 2, 3, and 4, respectively, and the four transducers connected to the second transducer switching control box are coded as 5, 6, 7, and 8, respectively.

[0058] In this embodiment, each transducer switching control box also performs Modbus communication with the ultrasonic generator. The ultrasonic generator sends a communication signal to the transducer switching control box through the Modbus channel. After the transducer switching control box receives the communication signal, it controls the transducer with the specified number to switch according to the communication signal and starts working.

[0059] In this embodiment, since each transducer has its own operating frequency, the connected transducer needs to be debugged and the debugged data must be saved in the memory of the ultrasonic generator before use. For example, after the ultrasonic generator is connected to transducer No. 1, the vibration system (including transducer + amplitude transformer + mold) scanning function is turned on to obtain the operating frequency and control parameters of transducer No. 1, and then the welding effect of transducer No. 1 is tested. When the effect is satisfactory, the operating frequency and control parameters are stored as the control parameters of transducer No. 1 of the ultrasonic generator, and so on until all transducers are debugged.

[0060] The ultrasonic welding transducer switching control box cascade system has the following advantages:

[0061] 1) Significantly improved scalability: The transducer switching control box adopts a cascade design, allowing multiple transducer switching control boxes to be used in series to achieve unlimited expansion, breaking the limitation of traditional fixed number transducer control. Users can flexibly increase the number of transducer switching control boxes according to actual needs without replacing the entire system, which greatly improves scalability and ease of use.

[0062] 2) Automatic numbering mechanism simplifies configuration; innovative use of timing control signals to achieve automatic numbering of transducer switching control boxes and transducers eliminates the need for manual configuration. When adding a new transducer switching control box, simply cascade the new transducer switching control box after the last transducer switching control box, so that the number is automatically assigned at the next power-on, greatly simplifying the system expansion and maintenance process and reducing the difficulty of development.

[0063] 3) Unified communication protocol improves compatibility; all transducer switching control boxes use the same Modbus address to connect to the ultrasonic generator, simplifying the complexity of the communication protocol. Unified communication method improves compatibility and facilitates future upgrades and maintenance.

[0064] 4) Efficient command processing mechanism: The communication signal sent by the ultrasonic generator can be received by all transducer switching control boxes at the same time, but only the relevant transducer switching control box responds, which improves the response speed and efficiency, reduces unnecessary communication overhead, and optimizes system performance.

[0065] 5) Significant cost-effectiveness; there is no need to design multiple transducer switching control boxes for different numbers of transducers, which reduces R&D costs. The use of standardized transducer switching control boxes can reduce inventory types and inventory costs. Users can gradually expand the system according to their needs, avoiding a one-time large investment.

[0066] 6) Easy operation and maintenance: Automatic numbering and unified communication protocols greatly simplify the configuration and maintenance process. The standardized transducer switching control box facilitates troubleshooting and replacement, improving maintainability.

[0067] 7) Strong adaptability; suitable for various application scenarios that require multiple transducers to switch, such as automobile door panel puncture welding and other fields. Flexible expansion capabilities can easily adapt to production needs of different scales.

[0068] 8) Improve production efficiency; fast transducer switching and efficient communication mechanisms help improve the overall efficiency of the production line. Scalability allows the production line to be quickly adjusted according to demand, reducing downtime.

[0069] 9) Save space; compared with the traditional solution that requires multiple transducer switching control boxes of different models, the use of a standardized transducer switching control box can make more effective use of the equipment installation space.

[0070] 10) Future upgrade potential: unified communication protocol and modular design facilitate future functional expansion and performance improvement. Flexibility makes it easy to adapt to new transducers or new application requirements that may appear in the future.

[0071] Further, see Figure 2 ,The transducer switching control box includes: a communication module, a control module and a switching circuit;

[0072] Communication module: connected to the input end of the control module, the first input end and the second input end of the transducer switching control box; the communication module is used for bidirectional data exchange with the ultrasonic generator;

[0073] The output end of the control module is connected to the switching circuit; the control module is used to complete the numbering of the transducers and generate the switching control instructions; the switching control instructions are generated according to the communication signal;

[0074] The switching circuit includes multiple cascaded relays; the first contact of the first cascaded relay receives a high-voltage transducer drive signal, the first contacts of other cascaded relays are connected to the second contacts of the previous relay, and the second contact of the last cascaded relay is connected to the first output end of the transducer switching control box; the control end of each relay receives a switching control instruction.

[0075] In this embodiment, the communication module can be a Modbus module, the ultrasonic generator sends a communication signal and a timing control signal to the transducer switching control box through the communication module, and the transducer switching control box feeds back response information to the ultrasonic generator through the communication module. When the control module receives the timing control signal forwarded by the communication module, the connected transducers are numbered, and when the control module receives the communication signal forwarded by the communication module, the control module parses the transducer that needs to be switched in the communication signal, and generates a switching control instruction and forwards it to the switching circuit connected to the specified transducer.

[0076] In this embodiment, see Figure 3 , the switching circuit includes 6 cascaded relays, among which the relays can be selected from high-voltage relays with an insulation voltage between the coil and the contact greater than 4000Vac, and the current should be greater than 5A. In each relay, terminal 2 is the first contact, terminal 3 is the second contact, and terminals 1 and 4 are control terminals, wherein terminal 1 is one pole of the driving coil of the high-voltage relay, connected to a 12V power supply, and terminal 2 is the other pole of the driving coil of the high-voltage relay, receiving the switching control instruction. Terminals JT1 and JT2 are the input interfaces of the switching circuit, terminal JT1 inputs the high-voltage transducer drive signal, which is used to drive the transducer, and terminal JT2 is connected to the negative pole of the transducer input coaxial connector and grounded; terminals JT3 and JT4 are the output interfaces of the switching circuit, terminal JT3 outputs the high-voltage transducer drive signal, and terminal JT4 is grounded. The first contact of the first relay is connected to terminal JT1, the first contacts of other relays are connected to the second contact of the previous relay, and the second contact of the last relay is connected to terminal JT3. Since each transducer switch control box controls 4 transducers, the transducer switch control box contains 4 Figure 3 The switching circuit shown. The switching control instruction is used to control the first contact and the second contact of the relay to disconnect or connect, thereby realizing the switching of the working state of the transducer.

[0077] In this embodiment, Figure 3The working principle is as follows: the high-voltage transducer drive signal enters the switching circuit from port JT1, and the high-voltage transducer drive signal passes through terminals 2 and 3 of 6 series-connected relays (RL1-RL6) in turn to form a controllable switch. When the connected transducer needs to be used, the level signal of the switching control instruction is changed to control the connection of the two contacts of each relay so that the high-voltage transducer drive signal can be smoothly output to the transducer. Ports JT2 and JT4 are grounded to ensure the safety and stability of the circuit.

[0078] In this embodiment, the first input end of the transducer switching control box is connected to the ultrasonic generator and the previous transducer switching control box through a timing line, and the second input end of the transducer switching control box is connected to the ultrasonic generator through a communication line. The timing line and the communication line can share a network cable with a shielding layer, and use differential transmission of signals, such as using the Modbus RTU protocol based on RS485, and the timing line uses differential transmission, which is combined with the twisted pair structure and shielding layer of the network cable, greatly improving the reliability of the transmission signal. When there are many cascade system interfaces, differential signal transmission is particularly important.

[0079] The transducer switching control box has the following advantages:

[0080] 1) Modular structure; by connecting multiple relays in series, the switching capacity can be flexibly expanded.

[0081] 2) High voltage isolation: Using relays for switching can effectively isolate high voltage and improve system safety.

[0082] 3) It can achieve efficient, safe and flexible control of multiple transducers to meet the needs of complex ultrasound application scenarios.

[0083] Furthermore, the transducer switching control box also includes:

[0084] Display module: connected to the control module; the display module is used to display the communication connection status of the transducer switching control box and the working status of the relay.

[0085] In the present embodiment, the transducer switching control box also includes a display module, which displays the communication connection state of the transducer switching control box (for example, the Modbus channel is connected or disconnected) and the working state of the relay (for example, the two contacts of the relay are connected or disconnected). The transducer switching control box also includes a power module, which provides the required working voltage for the transducer switching control box to ensure the stable operation of the system. For example, the display module can also include multiple LED indicator lights. When the transducer switching control box is powered on, the self-test program is started, and the LED indicator lights of the display module are lit one by one to ensure that the LED indicator lights can be used normally. The communication connection state of the transducer switching control box and the working state of the relay are indicated by the LED indicator lights, which is simple and clear. In order to increase stability, the transducer switching control box can also perform some safeguards, such as the transducer switching control box saves the control box number to a non-volatile memory, because the transducer switching control box in normal use usually does not change the control box number at will after debugging. Therefore, when the control box number received at other times is inconsistent with the stored control box number, an alarm can be issued through the display module to ensure that the debugging personnel can find and deal with it in time.

[0086] In this embodiment, the transducer switching control box also includes an independent watchdog peripheral, so that when the control module crashes, it can be restarted in time and work through the control box number stored in the non-volatile memory in advance. The watchdog peripheral can also monitor whether the communication module is working properly and reinitialize after the communication module crashes.

[0087] A cascading method for switching control boxes of ultrasonic welding transducers is run on the above system; the method comprises:

[0088] When the system is powered on, the ultrasonic generator sends a timing control signal;

[0089] When the transducer switching control box receives the timing control signal, it calculates the time difference between the timing control signal reception time and the system power-on time; determines the control box number according to the time difference, and transmits the timing control signal to the next transducer switching control box after delaying according to the time threshold;

[0090] The transducer switching control box determines the transducer number of the transducer according to the control box number;

[0091] The ultrasonic generator sends a communication signal;

[0092] When the transducer switching control box receives the communication signal, it parses and obtains the transducer number in the communication signal, which is defined as the target number;

[0093] When the transducer switching control box detects that the transducer number of the connected transducer includes the target number, the transducer corresponding to the target number is switched to start working.

[0094] In this embodiment, Figure 4 , 5 Switching control box for transducer ( Figure 4 , 5 The cascade method of the ultrasonic generator (referred to as the switching box in the text). When the system is powered on, each device in the system records the system power-on time. The ultrasonic generator sends a timing control signal, that is, a high-level signal, to start the automatic numbering process of the transducer switching control box. After the first transducer switching control box receives the high-level timing control signal, it calculates the time difference between the timing control signal reception time and the system power-on time. Since the ultrasonic generator immediately generates the timing control signal when the system is powered on and sends it to the first transducer switching control box, the time difference is basically 0. The transducer switching control box can recognize that it is the first in the cascade and determine that its own control box number is 1. After the first transducer switching control box is numbered, it delays according to the time threshold, for example, a delay of 100ms, and passes the timing control signal to the second transducer switching control box.

[0095] After the second transducer switching control box receives the timing control signal, it calculates the time difference between the timing control signal reception time and the system power-on time. For example, if the time difference is about 100ms (the time taken by the transducer switching control box to be numbered is ignored here), the transducer switching control box can recognize that it is the second one in the cascade and determine that its own control box number is 2. After the second transducer switching control box is numbered, it delays 100m according to the time threshold and passes the timing control signal to the third transducer switching control box, and so on, to complete the numbering of all transducer switching control boxes. When the transducer switching control box determines its own control box number, it determines the transducer number of the transducer according to the transducer switching control box number, and completes the numbering of all transducer switching control boxes and transducers in the system in turn.

[0096] In this embodiment, the ultrasonic generator uses the Modbus protocol to send a communication signal to all transducer switching control boxes. After receiving the communication signal, the transducer switching control box defines the transducer number to be switched in the communication signal as the target number. When the transducer switching control box detects that the transducer number in the connected transducer includes the target number, it means that the transducer switching control box is connected to the target transducer. At this time, the transducer switching control box responds, and the transducer corresponding to the switching target number starts to work. The transducer switching control box that is not connected to the target transducer does not respond.

[0097] Furthermore, the control box number is a multiple of the time difference and the time threshold + 1.

[0098] In this embodiment, assuming that the time threshold is 100ms, the time difference calculated by the first transducer switching control box is approximately 0, the multiple is 0, and the control box number is 1. The time difference calculated by the second transducer switching control box is approximately 1 time threshold (delay processing of the first transducer switching control box), the multiple is 1, and the control box number is 2. The time difference calculated by the third transducer switching control box is approximately 2 time thresholds (delay processing of the first and second transducer switching control boxes), the multiple is 2, and the control box number is 3, and so on.

[0099] Furthermore, the transducer numbers of the transducers connected to the transducer switching control box are: total number of transducers*(control box number-1)+1~total number of transducers*control box number; the total number of transducers is the number of transducers connected to the transducer switching control box.

[0100] In this embodiment, the number range of the transducers controlled by each transducer switching control box is: total number of transducers * (control box number - 1) + 1 ~ total number of transducers * control box number. For example, assuming that each transducer switching control box controls 4 transducers, and the total number of transducers = 4, then the number range of the transducers controlled by the first transducer switching control box is: 4*0+1~4*1, that is, 1~4; the number range of the transducers controlled by the second transducer switching control box is: 4*1+1~4*2, that is, 5~8; the number range of the transducers controlled by the third transducer switching control box is: 4*2+1~4*3, that is, 9~12, and so on. When the transducer switching control box is connected to 8 or 16 transducers, the total number of transducers is 8 or 16.

[0101] Furthermore, switching the transducer corresponding to the target number to start working specifically includes:

[0102] generating a switching control instruction;

[0103] The switching control instruction is sent to the relay connected to the transducer corresponding to the target number, and the relay is controlled to close, so that the transducer corresponding to the target number is connected to the ultrasonic generator and receives the high-voltage transducer driving signal output by the ultrasonic generator.

[0104] In this embodiment, after the transducer switching control box parses the target number, it starts to address the transducer. Since the transducer coding range corresponding to the transducer switching control box is: total number of transducers * (control box number - 1) + 1 ~ total number of transducers * control box number, when the target number falls within the transducer coding range, it is considered that the target transducer exists. Then the transducer switching control box generates a switching control instruction; sends the switching control instruction to the relay connected to the transducer corresponding to the target number, controls the relay to close, so that the transducer corresponding to the target number is connected to the ultrasonic generator and receives the high-voltage transducer drive signal output by the ultrasonic generator.

[0105] This approach has the following advantages:

[0106] 1) A flexible addressing mechanism is adopted to support large-scale transducer array control.

[0107] 2) Efficient command distribution; broadcast command transmission and target selective response.

[0108] Furthermore, after the system is powered on, it also includes:

[0109] The transducer switching control box establishes a communication connection with the ultrasonic generator according to the Modbus address of the ultrasonic generator.

[0110] In this embodiment, after the system is powered on, the transducer switching control box establishes a communication connection with the ultrasonic generator according to the Modbus address of the ultrasonic generator, and the Modbus address can be an address agreed in advance between the ultrasonic generator and the transducer switching controller, and completes the initialization of the communication module in the transducer switching control box, and the transducer switching control box waits to receive the communication signal of the ultrasonic generator. The initialization process of the communication module does not need to wait for the numbering process to be completed. The ultrasonic generator can be a Modbus host, and the transducer switching control box is a Modbus slave.

[0111] Furthermore, after the transducer corresponding to the switching target number starts to work, the method further includes:

[0112] The transducer switching control box corresponding to the target number generates a Modbus response message and returns it to the ultrasonic generator;

[0113] The ultrasonic generator determines whether the timing control signal is correctly executed according to the received Modbus response information, and performs shutdown error, reminder or ignore operation.

[0114] In this embodiment, when the transducer switching control box completes the switching of the transducer, the transducer switching control box generates a Modbus response message and returns it to the ultrasonic generator to inform the ultrasonic generator that the switching of the transducer has been completed. The ultrasonic generator determines whether the timing control signal is correctly executed and whether it is necessary to perform shutdown error reporting, reminder or ignore operations based on the Modbus response information.

[0115] In this embodiment, the method uses an improved Modbus protocol. In the standard Modbus protocol communication process, the slave will reply to the host after receiving the communication information. Therefore, when multiple transducer switching control boxes all reply, it will cause timing problems, and the ultrasonic generator cannot obtain the reply that the command is correctly executed. Therefore, in the improved Modbus protocol used by this method, only the transducer switching control box corresponding to the target number will reply to the ultrasonic generator.

[0116] In this embodiment, if the ultrasonic generator does not receive the Modbus response information from the transducer switching control box within the predetermined waiting time after sending a communication signal, it may try to send the communication signal again or multiple times. When the Modbus response information from the transducer switching control box is still not received after sending it again or multiple times, the ultrasonic generator may issue a warning prompt.

[0117] The method provided in the embodiment of the present invention is briefly described. For matters not mentioned in the embodiment part, reference can be made to the corresponding contents in the aforementioned embodiment.

[0118] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents. These modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and specification of the present invention.

Claims

1. An ultrasonic welding transducer switching control box cascade system, comprising an ultrasonic generator, characterized in that: It also includes a plurality of cascaded transducer switching control boxes, wherein a plurality of first output ends of each transducer switching control box are connected to a plurality of transducers; The first input end of the first transducer switching control box of the cascade is connected to the first output end of the ultrasonic generator, and the first input ends of other transducer switching control boxes of the cascade are connected to the second output end of the previous transducer switching control box; the first output end of the ultrasonic generator and the second output end of each transducer switching control box output a timing control signal; the timing control signal is used for the transducer switching control box to complete the numbering of the transducers; The second input end of the transducer switching control box is connected to the second output end of the ultrasonic generator; the second output end of the ultrasonic generator outputs a communication signal; the communication signal is used for the transducer switching control box to complete the switching of the transducer with a specified number.

2. The ultrasonic welding transducer switching control box cascade system according to claim 1 is characterized in that: The transducer switching control box includes: a communication module, a control module and a switching circuit; Communication module: connected to the input end of the control module, the first input end and the second input end of the transducer switching control box; the communication module is used for bidirectional data exchange with the ultrasonic generator; The output end of the control module is connected to the switching circuit; the control module is used to complete the numbering of the transducers and generate a switching control instruction; the switching control instruction is generated according to the communication signal; The switching circuit includes multiple cascaded relays; the first contact of the first cascaded relay receives a high-voltage transducer drive signal, the first contacts of other cascaded relays are connected to the second contacts of the previous relay, and the second contact of the last cascaded relay is connected to the first output end of the transducer switching control box; the control end of each relay receives the switching control instruction.

3. The ultrasonic welding transducer switching control box cascade system according to claim 2 is characterized in that: The transducer switching control box also includes: Display module: connected to the control module; the display module is used to display the communication connection status of the transducer switching control box and the working status of the relay.

4. The ultrasonic welding transducer switching control box cascade system according to claim 2 is characterized in that: The switching control instruction is used to control the first contact and the second contact of the relay to be disconnected or connected, thereby realizing the switching of the working state of the transducer.

5. A cascading method for switching control boxes of ultrasonic welding transducers, characterized in that: Running on a system as claimed in any one of claims 1 to 4; the method comprising: When the system is powered on, the ultrasonic generator sends the timing control signal; When the transducer switching control box receives the timing control signal, it calculates the time difference between the timing control signal reception time and the system power-on time; determines the control box number according to the time difference, and transmits the timing control signal to the next transducer switching control box after a delay according to the time threshold; The transducer switching control box determines the transducer number of the transducer according to the control box number; The ultrasonic generator sends the communication signal; When the transducer switching control box receives the communication signal, it parses and obtains the transducer number in the communication signal, which is defined as the target number; When the transducer switching control box detects that the transducer number of the connected transducers includes the target number, the transducer corresponding to the target number is switched to start working.

6. The method for cascading an ultrasonic welding transducer switching control box according to claim 5, characterized in that: The control box number is a multiple of the time difference and the time threshold + 1.

7. The method for cascading an ultrasonic welding transducer switching control box according to claim 5, characterized in that: The transducer numbers of the transducers connected to the transducer switching control box are: total number of transducers*(control box number-1)+1~total number of transducers*control box number; the total number of transducers is the number of transducers connected to the transducer switching control box.

8. The method for cascading an ultrasonic welding transducer switching control box according to claim 5, characterized in that: The transducer corresponding to the switching target number starts working specifically including: generating the switching control instruction; The switching control instruction is sent to a relay connected to the transducer corresponding to the target number, and the relay is controlled to close, so that the transducer corresponding to the target number is connected to the ultrasonic generator and receives the high-voltage transducer driving signal output by the ultrasonic generator.

9. The method for cascading an ultrasonic welding transducer switching control box according to claim 5, characterized in that: After the system is powered on, it also includes: The transducer switching control box establishes a communication connection with the ultrasonic generator according to the Modbus address of the ultrasonic generator.

10. The method for cascading an ultrasonic welding transducer switching control box according to claim 9, characterized in that: After the transducer corresponding to the switching target number starts working, it also includes: The transducer switching control box corresponding to the target number generates Modbus response information and returns it to the ultrasonic generator; The ultrasonic generator determines whether the timing control signal is correctly executed according to the received Modbus response information, and performs shutdown error, reminder or ignore operation.

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