Method, equipment, medium and product for determining the working pressure range of digital ultrasonic welder

Abstract

This application relates to the field of ultrasonic technology, and discloses a method, equipment, medium, and product for determining the working pressure range of a digital ultrasonic welding machine. The method includes: controlling the welding head to press down before contacting the workpiece and initiating ultrasonic power supply frequency search to collect the pressure of the welding head and the frequency of the ultrasonic power supply at different times; generating a pressure-frequency relationship curve; obtaining a first pressure range based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined working frequency range; sampling at least two pressure sample values ​​within the first pressure range; performing frequency sweeping at each pressure sample value to obtain a frequency sweep curve; acquiring the phase difference of the frequency sweep curve corresponding to each pressure sample value; and determining the working pressure range of the digital ultrasonic welding machine based on the phase difference. By adopting this solution, users can easily understand the performance of the welding machine and avoid problems caused by using inappropriate working parameters that affect the welding effect.

Description

Technical Field

[0001] This application relates to the field of ultrasonic technology, and in particular to a method, equipment, medium, and product for determining the working pressure range of a digital ultrasonic welding machine. Background Technology

[0002] In recent years, with the rapid development of science and technology, ultrasonic welding technology has been applied more and more widely.

[0003] In existing ultrasonic welding methods, ultrasonic welding machines that use servo motors or cylinders for welding pressure control are becoming increasingly common. For ultrasonic welding control, different welding pressures result in different loads, leading to frequent changes in welding parameters, including pressure, as required by the application. This results in a relatively large range of load variations, placing higher demands on the design and control of the ultrasonic power supply.

[0004] High-power ultrasonic power supplies currently employ a full-bridge inverter with a matching circuit to achieve the required drive voltage output for ultrasonic transducers. However, due to limitations in the parameters of components such as inductors and capacitors used in the matching circuit, this method requires consideration of the transducer and operating conditions to achieve a good matching effect, thus limiting its applicability to a wide range of loads.

[0005] Therefore, in situations where welding pressure needs to be adjusted, resulting in significant load variations, ultrasonic power supplies typically cannot guarantee normal operation under all circumstances. Thus, for users, understanding the controllable range in advance is a crucial prerequisite for scheduling welding work. Summary of the Invention

[0006] One objective of this application is to provide a method, device, medium, and product for determining the working pressure range of a digital ultrasonic welding machine, at least to address the problem of insufficient matching of welding pressure range due to limitations in electronic components. This application involves controlling the welding head to press down before contacting the workpiece and initiating ultrasonic power supply frequency search to collect the welding head pressure and ultrasonic power supply frequency at different times; generating a pressure-frequency relationship curve based on the collected pressure and ultrasonic power supply frequency at different times; obtaining a first pressure range based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined working frequency range; within the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values; frequency sweeping is performed at each pressure sampling value to obtain a sweep curve corresponding to each pressure sampling value; the phase difference of the sweep curves corresponding to each pressure sampling value is obtained; and the working pressure range of the digital ultrasonic welding machine is determined based on the phase difference. By adopting this solution, the corresponding actions and data acquisition can be automated by combining welding pressure control with the working mode of the digital ultrasonic power supply, obtaining corresponding curves that facilitate users' understanding of the welding machine's performance and avoid the problem of using inappropriate working parameters affecting the welding effect.

[0007] To achieve the above objectives, some embodiments of this application provide the following aspects:

[0008] In a first aspect, some embodiments of this application also provide a method for determining the working pressure range of a digital ultrasonic welding machine, including:

[0009] Before contacting the workpiece, the welding head is controlled to press down, and the ultrasonic power supply frequency search is started to collect the pressure of the welding head and the frequency of the ultrasonic power supply at different times.

[0010] Based on the pressure of the welding head and the frequency of the ultrasonic power supply at different times, a pressure-frequency relationship curve is generated.

[0011] The first pressure range is obtained based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined operating frequency range;

[0012] Within the first pressure range, at least two pressure sample values ​​are obtained by sampling according to the preset sampling rules;

[0013] Frequency sweep is performed at each pressure sampling value to obtain the frequency sweep curve corresponding to each pressure sampling value;

[0014] Obtain the phase difference of the sweep curve corresponding to each pressure sample value;

[0015] The working pressure range of the digital ultrasonic welding machine is determined based on the phase difference.

[0016] Secondly, some embodiments of this application also provide an electronic device, the electronic device comprising: one or more processors; and a memory storing computer program instructions, which, when executed, cause the processor to perform the steps of the method described above.

[0017] Thirdly, some embodiments of this application also provide a computer-readable medium having computer program instructions stored thereon, which can be executed by a processor to implement the method described above.

[0018] Fourthly, some embodiments of this application also provide a computer program product, including a computer program / instructions that, when executed by a processor, implement the steps of the method described above.

[0019] Compared with related technologies, the solution provided in this application involves controlling the welding head to press down before contacting the workpiece and initiating ultrasonic power supply frequency search to collect the welding head pressure and ultrasonic power supply frequency at different times. Based on the collected welding head pressure and ultrasonic power supply frequency at different times, a pressure-frequency relationship curve is generated. A first pressure range is obtained based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined working frequency range. Within the first pressure range, at least two pressure sampling values ​​are obtained by sampling according to a preset sampling rule. Frequency sweeping is performed at each pressure sampling value to obtain a sweep curve corresponding to each pressure sampling value. The phase difference of the sweep curve corresponding to each pressure sampling value is obtained. The working pressure range of the digital ultrasonic welding machine is determined based on the phase difference. By adopting this solution, the corresponding actions and data acquisition can be automated by combining welding pressure control with the working mode of the digital ultrasonic power supply, obtaining corresponding curves that facilitate users' understanding of the welding machine's performance and avoid problems caused by using inappropriate working parameters that affect the welding effect. Attached Figure Description

[0020] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0021] Figure 1 This is an exemplary flowchart of a method for determining the working pressure range of a digital ultrasonic welding machine according to some embodiments of this application;

[0022] Figure 2 This is a schematic diagram of the pressure-frequency relationship curves provided according to some embodiments of this application;

[0023] Figure 3This is a schematic diagram of a sweep frequency curve with a pressure of F1 provided according to some embodiments of this application;

[0024] Figure 4 This is a schematic diagram of a frequency sweep curve with a pressure of F2 according to some embodiments of this application;

[0025] Figure 5 This is a schematic diagram of a pressure-phase difference curve provided according to some embodiments of this application;

[0026] Figure 6 An exemplary structural diagram of the electronic device is disclosed. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0028] First Embodiment

[0029] The first embodiment of this application relates to a method for determining the working pressure range of a digital ultrasonic welding machine. For example... Figure 1 As shown, the method is executed by a management tool and may include the following steps:

[0030] Step S101: Before contacting the workpiece, start controlling the downward pressure of the welding head and start the ultrasonic power frequency search to collect the pressure of the welding head and the frequency of the ultrasonic power at different times.

[0031] Ultrasonic welding utilizes high-frequency vibration waves transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces rub against each other, causing fusion between molecular layers. An ultrasonic generator converts 50 / 60 Hz current into 15, 20, 30, or 40 kHz electrical energy. This high-frequency energy is then converted into mechanical motion of the same frequency by a transducer. This mechanical motion is then transmitted to the welding head via an amplitude converter. The welding head transfers the received vibrational energy to the joint of the workpieces to be welded. In this area, the vibrational energy is converted into heat energy through friction, melting the plastic. Welding methods include fusion welding, where the ultrasonic welding head, vibrating at ultra-high frequency, under moderate pressure, causes frictional heat to instantly melt and join the two plastic surfaces. Riveting welding involves pressing the ultrasonic welding head, vibrating at ultra-high frequency, against the protruding tip of a plastic part, causing it to instantly heat and melt into a rivet shape, mechanically joining materials of different materials together. Embedding: Using the transmission of the welding head and appropriate pressure, metal parts are instantly squeezed into pre-drilled plastic holes and fixed at a certain depth. Molding: A concave welding head is pressed against the outer ring of the plastic part. After the welding head emits ultrasonic ultra-high frequency vibrations, the plastic melts and molds, encapsulating the metal object and fixing it in place. Spot welding: Two pieces of plastic are fused together at specific points without the need for pre-designed weld lines, or for larger workpieces or workpieces where pre-designed weld lines are not suitable, achieving a fusion effect through spot welding. Cutting and sealing: Utilizing the principle of instantaneous ultrasonic vibration, synthetic fiber fabrics are cut. It has advantages such as fast welding speed, high welding strength, good sealing performance, low cost, cleanliness and no pollution, and stable welding process.

[0032] Ultrasonic welding power supply control primarily aims to ensure the stable and efficient output of high-frequency electrical energy from the ultrasonic welding power supply. This energy drives the transducer to generate stable mechanical vibrations, thereby achieving high-quality ultrasonic welding. Simultaneously, precise power supply control allows for the adjustment of welding parameters based on different welding materials, workpiece shapes, and welding requirements, optimizing the welding process, improving welding efficiency and quality, and extending equipment lifespan. Automatic frequency tracking is crucial because the resonant frequency of the ultrasonic transducer can drift with changes in ambient temperature and load. Automatic frequency tracking technology monitors the transducer's operating frequency in real time and automatically adjusts the output frequency of the ultrasonic power supply to maintain it near the transducer's resonant frequency, ensuring maximum mechanical vibration efficiency and improving welding effect and stability. Power control precisely controls the output power of the ultrasonic power supply based on the characteristics of the welding material, workpiece thickness, and dimensions to provide appropriate welding energy. Power control methods include constant power control and time-power control, which can be achieved by adjusting parameters such as the power supply's output voltage and current to ensure consistent welding quality. Phase difference control monitors and controls the phase difference between the voltage and current across the ultrasonic transducer to optimize energy transfer and conversion during welding. By adjusting the phase difference, the transducer can better absorb and convert electrical energy into mechanical energy, improving welding efficiency and quality.

[0033] The welding head is a component in welding equipment that directly contacts the workpiece and transmits energy to achieve welding. Its shape, material, and performance affect the welding quality and effect.

[0034] A frequency sweep curve is a curve obtained through frequency sweeping operations. It reflects the relationship between a physical quantity (such as voltage, current, amplitude, etc.) and frequency within a certain frequency range. In ultrasonic welding, it can be used to analyze and evaluate relevant characteristics during the welding process.

[0035] Among them, the welded workpiece is a component or other object that needs to be connected through welding process, and it is the object targeted by the welding operation.

[0036] A welding head is a component on an ultrasonic welding device that comes into direct contact with the workpiece to be welded, and is used to transmit ultrasonic energy to achieve welding.

[0037] Pressure refers to the magnitude of the force exerted by the welding head on the workpiece during welding, reflecting factors such as the tightness of the contact during welding.

[0038] The ultrasonic power supply frequency, which is the parameter output by the ultrasonic power supply that determines the speed of ultrasonic vibration, will affect the welding effect depending on the frequency.

[0039] In this solution, controlling the downward pressure involves using a corresponding mechanical transmission mechanism or electrical control module to move the welding head toward the workpiece according to a set program or instruction, so as to achieve a suitable contact position. The purpose is to make the welding head contact the workpiece and prepare for welding.

[0040] Frequency search is the process by which an ultrasonic power supply automatically and sequentially changes its output frequency within a specific frequency range according to certain preset rules. Frequency search can identify the optimal frequency for the current workpiece and welding conditions, or comprehensively acquire various welding-related parameters at different frequencies, providing a data foundation for subsequently determining suitable welding parameters.

[0041] Pressure data of the welding head is obtained by a pressure sensor installed on the equipment, and power frequency data is obtained by a data acquisition module connected to the ultrasonic power supply. The pressure and frequency values ​​corresponding to these different times are collected and recorded for subsequent analysis and processing.

[0042] Step S102: Generate a pressure-frequency relationship curve based on the pressure of the welding head and the frequency of the ultrasonic power supply at different times.

[0043] The pressure-frequency relationship curve can be a graph formed by connecting the points corresponding to the pressure and frequency data collected at different times with the welding head pressure as the horizontal axis and the ultrasonic power supply frequency as the vertical axis. It is used to intuitively present the correlation and changes between the two.

[0044] In this solution, the generation method utilizes the collected pressure and frequency data at different times. Through corresponding data analysis software or the built-in computing module of the device, these discrete data points are fitted into a continuous curve according to the mathematical correspondence, so as to clearly show the changing pattern between pressure and frequency, which facilitates subsequent judgment and operation based on the curve.

[0045] In this solution, optionally, after controlling the downward pressure of the welding head and starting the ultrasonic power supply frequency search before contacting the workpiece, the method further includes:

[0046] When the preset termination condition is met, the welding head pressing down and the generator frequency search are stopped, and data recording is completed.

[0047] Preset termination conditions can be pre-set based on factors such as welding process requirements, equipment operation safety specifications, and data acquisition integrity. They are used to determine when to end the welding head pressing down and the generator frequency sweeping operation. For example, reaching the specified frequency search duration, collecting a sufficient number of data points, or the occurrence of specific welding parameter changes can all be used as preset termination conditions.

[0048] Data recording refers to the process of saving various welding-related data, such as welding head pressure, ultrasonic power frequency, search curve, and phase difference, collected during the welding process, in a specific format using storage devices (such as built-in storage chips or external data storage hard drives) for subsequent review, analysis, and process optimization.

[0049] Stopping the downward pressure is achieved by sending a stop command to the mechanical or electrical actuator that controls the movement of the welding head, causing it to cease moving towards the workpiece. This prevents the welding head from being excessively pressed down, which could damage the workpiece or fail to meet welding process requirements, and ensures that the operation ends according to the established specifications.

[0050] Stopping frequency sweep can be achieved by sending a stop frequency sweep command to the control system of the ultrasonic power generator, causing the generator to stop automatically switching frequencies within the frequency range, avoiding unnecessary energy consumption and ensuring that data acquisition ends at an appropriate point, thus guaranteeing the validity and accuracy of the acquired data.

[0051] The built-in data acquisition and recording program in the device stores the previously collected welding-related data in an orderly manner into the corresponding storage medium according to the preset data format (such as table format, specific encoding format, etc.), thereby completing the entire data recording process and facilitating subsequent review and analysis of the welding process and results.

[0052] In this scheme, optionally, the preset termination condition includes the welding head pressure reaching a predetermined maximum pressure, or the ultrasonic power supply frequency search alarm.

[0053] The predetermined maximum pressure can be set before the welding operation begins, based on factors such as the material properties, structural characteristics, and performance of the welding equipment itself. It is the upper limit of the pressure that the welding head can apply. Once the welding head pressure reaches this value, the relevant conditions in the preset termination conditions are met, and the corresponding operation needs to be stopped to avoid adverse effects on the workpiece or equipment.

[0054] The ultrasonic power supply frequency search alarm is a warning signal issued by the ultrasonic power supply itself during the frequency sweep process when it detects situations that do not meet the normal operating requirements, such as abnormal deviation of the output frequency from the set range, potential faults in the internal circuit, or related parameters exceeding the normal fluctuation range during the frequency sweep. This signal alerts the operator that there is a problem with the current frequency sweep. This situation is also set as one of the preset termination conditions. Once triggered, the relevant operation must be stopped to ensure safety and avoid invalid data acquisition.

[0055] This solution involves using pressure sensors installed at relevant parts of the welding head to monitor the pressure applied by the welding head to the workpiece in real time. When the pressure data fed back by the sensor is equal to the preset maximum pressure value, it is determined that this condition has been met, and subsequent operations should be stopped according to the rules.

[0056] The ultrasonic power supply can be equipped with corresponding fault detection modules and alarm triggering mechanisms. During the frequency sweeping process, these modules will continuously monitor and analyze various parameters of the frequency sweep (such as frequency, current, voltage, etc.). Once an abnormal situation is detected that meets the preset alarm triggering criteria, an alarm will be triggered by emitting audible and visual signals to inform the operator of the current frequency sweeping situation, thereby triggering the preset termination condition to take effect, and subsequent operations need to be stopped accordingly.

[0057] Figure 2 This is a schematic diagram of the pressure-frequency relationship curves provided according to some embodiments of this application. For example... Figure 2 As shown, the operating frequency range corresponding to the design parameters of the ultrasonic transducer and welding head used is [f] d1 ,f d2 The first pressure range [F1, F2] is obtained by considering the minimum pressure required for welding and the pressure-frequency curve, where F1 is the minimum pressure required for welding and F2 is the pressure at the frequency f. d2 The pressure value.

[0058] Step S103: Based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined operating frequency range, a first pressure range is obtained;

[0059] Minimum pressure can be the minimum pressure applied by the welding head to the workpiece during the welding process to ensure a reliable connection of the weld joint. Below this value, a good welding effect may not be achieved.

[0060] The operating frequency range can be determined in advance based on the material, shape, and other characteristics of the workpiece to be welded, as well as the performance of the ultrasonic welding equipment itself. It is a range of ultrasonic power supply frequencies suitable for welding operations.

[0061] The maximum pressure can be the highest pressure value that the welding head can apply to the workpiece during welding, taking into account that the workpiece will not be damaged due to excessive pressure, and based on the conditions corresponding to a predetermined working frequency range.

[0062] The first pressure range is a range of pressure values ​​defined by comprehensively considering the minimum pressure required for welding and the maximum pressure determined based on the working frequency range. Subsequent operations will be carried out within this range.

[0063] This solution determines the minimum pressure by using experience data from previous welding of this type or similar workpieces and welding process standard requirements. The operating frequency range is confirmed based on workpiece material characteristics analysis and equipment technical manual recommendations. The maximum pressure is determined by comprehensively considering factors such as the operating frequency range and the workpiece's pressure-bearing capacity. Finally, by comparing the minimum and maximum pressure values, the first pressure range is defined, which limits the range for subsequent sampling and other operations.

[0064] In this scheme, optionally, the predetermined operating frequency range is determined based on the design parameters of the ultrasonic transducer and the welding head.

[0065] Among them, the ultrasonic transducer is a device that can convert electrical energy into mechanical energy (in ultrasonic welding, it is usually the input electrical energy that is converted into mechanical energy in the form of ultrasonic vibration) or perform the reverse conversion. It is a key component in ultrasonic welding equipment, and its performance parameters have an important impact on the generation and effect of ultrasonic waves in the entire welding process.

[0066] The design parameters of the welding head can include specific specifications such as its shape, size, material, and resonant frequency. These parameters determine the efficiency of the welding head in transmitting ultrasonic energy during welding, its contact characteristics with the workpiece, and the range of vibration frequencies it can adapt to, playing a crucial role in the welding effect.

[0067] The operating frequency range refers to the range of ultrasonic power supply output frequencies suitable for the equipment to carry out welding work normally and efficiently during ultrasonic welding operations. Welding within this range can ensure welding quality and stable equipment operation. It is an important parameter range determined based on the characteristics of relevant components.

[0068] This approach begins by obtaining key performance parameters such as rated frequency and bandwidth from the ultrasonic transducer's instruction manual and technical handbook. Simultaneously, it gathers design parameters specified in the welding head design, such as resonant frequency and compatible frequency range. Then, considering the compatibility of both in actual welding work, and through theoretical calculations, simulation analysis, or referencing experience data from previous welding with similar equipment, the suitable operating frequency range for this welding operation is determined, providing a basis for subsequent frequency adjustments during the welding process.

[0069] This solution, through such settings, can obtain a reasonable initial pressure range, which can be used to calculate the subsequent working pressure range, thereby improving the control accuracy of the digital ultrasonic welding machine.

[0070] Step S104: Within the first pressure range, at least two pressure sampling values ​​are obtained by sampling according to a preset sampling rule;

[0071] Among them, the preset sampling rules can be pre-defined rules on how to select pressure sampling points (such as sampling interval, sampling quantity, etc.) based on factors such as welding process requirements and data analysis accuracy requirements before pressure sampling is carried out.

[0072] The pressure sampling value is a specific pressure value selected within the first pressure range according to the preset sampling rules, which is used for further analysis of welding-related characteristics under different pressures.

[0073] The sampling method is based on preset sampling rules, such as selecting specific pressure values ​​at equal intervals or according to a specific ratio within the first pressure range. The corresponding pressure values ​​are obtained using the device's data acquisition function. The purpose is to obtain multiple representative pressure points for subsequent frequency sweeping and analysis.

[0074] In this scheme, optionally, within the first pressure range, at least two pressure sample values ​​are obtained by sampling according to a preset sampling rule, including:

[0075] Within the first pressure range, pressure sampling values ​​are obtained by increasing the preset pressure interval each time.

[0076] The preset pressure interval can be a pressure difference between two adjacent pressure sampling values ​​that is pre-set based on factors such as the size of the first pressure range, the required sampling accuracy, and the needs of subsequent data analysis. It specifies the step size of the pressure increment when acquiring each pressure sampling value, which can ensure that the sampling value distribution is reasonable and conforms to the established sampling rules.

[0077] Figure 3 This is a schematic diagram of a frequency sweep curve with a pressure of F1 provided according to some embodiments of this application. Figure 4 This is a schematic diagram of a frequency sweep curve with a pressure of F2 according to some embodiments of this application. Figure 3 and Figure 4 As shown, the sweep frequency curve changes to some extent when the pressure changes.

[0078] This scheme first defines the starting and ending pressure values ​​of the first pressure range. Starting from the starting pressure value, subsequent pressure values ​​are calculated sequentially using a preset pressure interval as the increment. These pressure values ​​calculated step by step are recorded and collected as pressure sampling values. For example, if the starting pressure is 10N and the preset pressure interval is 2N, then pressure sampling values ​​of 10N, 12N, 14N, etc., can be obtained sequentially. This method ensures that a suitable and sufficient number of pressure sampling values ​​can be obtained within the first pressure range as required, for subsequent frequency sweeping and other related operations and analyses.

[0079] This scheme, through such a setting, ensures the rationality of each pressure sampling value and can evenly cover the first pressure range, making the results continuous and providing a data basis for subsequent determination of the working pressure range.

[0080] Step S105: Perform frequency sweep at each pressure sampling value to obtain the frequency sweep curve corresponding to each pressure sampling value;

[0081] The frequency sweep curve is a curve plotted by starting the ultrasonic power supply to sweep the frequency at a specific pressure sampling value. It is a curve that reflects the changes in the frequency sweep process under that pressure.

[0082] The frequency sweep method is similar to the frequency search start in step S101. Under the conditions corresponding to the set pressure sampling values, the ultrasonic power supply is operated to automatically scan the frequency and collect frequency and other data during this process. The purpose is to obtain the frequency sweep curves corresponding to different pressure sampling values ​​in order to analyze the influence of pressure on the frequency sweep effect.

[0083] Through the above frequency sweeping operation and the corresponding data acquisition and recording, the acquired data is organized according to time order or frequency order to form a curve that can intuitively reflect the frequency sweeping situation, that is, the frequency sweeping curve corresponding to each pressure sampling value, for subsequent analysis and comparison.

[0084] Step S106: Obtain the phase difference of the sweep frequency curve corresponding to each pressure sampling value;

[0085] Among them, the phase difference, in the sweep frequency curve corresponding to each pressure sampling value, refers to the difference between the phases of two sinusoidal alternating currents of the same frequency. In ultrasonic welding, it can reflect the differences in vibration and other aspects during the welding process under different pressures, which is of great significance for analyzing the welding status.

[0086] The acquisition method can be to use professional signal analysis instruments or the phase detection module built into the equipment to analyze and process the electrical signals involved in the sweep curve corresponding to each pressure sampling value, and extract the corresponding phase difference value, so as to determine the working pressure range based on the phase difference.

[0087] Step S107: Determine the working pressure range of the digital ultrasonic welding machine based on the phase difference.

[0088] The working pressure range of a digital ultrasonic welding machine can be the final determined range of pressure values ​​suitable for the digital ultrasonic welding machine to perform welding operations normally, efficiently and stably. Welding within this range can ensure welding quality.

[0089] The determination method is based on the phase difference data of the sweep frequency curves corresponding to each pressure sampling value obtained in the previous steps. Through specific algorithms, comparison standards or empirical judgment rules, the pressure range suitable for welding work is further precisely defined from the previously obtained first pressure range and other related intervals. This guides the actual welding operation and ensures the welding effect.

[0090] Before contacting the workpiece, the welding head is pressed down, and the ultrasonic power supply is activated to collect the welding head pressure and ultrasonic power supply frequency at different times. Based on the collected pressure and frequency data, a pressure-frequency relationship curve is generated. A first pressure range is obtained based on the minimum pressure required for welding and the maximum pressure determined according to a pre-defined operating frequency range. Within this first pressure range, at least two pressure sampling values ​​are obtained according to a preset sampling rule. A frequency sweep is performed at each pressure sampling value to obtain a sweep curve corresponding to each pressure sampling value. The phase difference of the sweep curves corresponding to each pressure sampling value is obtained. The operating pressure range of the digital ultrasonic welding machine is determined based on the phase difference. By adopting this scheme, the corresponding actions and data acquisition can be automated by combining welding pressure control with the operating mode of the digital ultrasonic power supply, resulting in corresponding curves that facilitate user understanding of the welding machine's performance and avoid problems caused by using inappropriate operating parameters that affect welding results.

[0091] In one embodiment, optionally, determining the operating pressure range of the digital ultrasonic welding machine based on the phase difference includes:

[0092] Obtain the minimum phase difference of the sweep curve corresponding to each pressure sample value;

[0093] Construct a pressure-phase difference minimum curve;

[0094] The minimum pressure required for welding is used as a first threshold for the working pressure range, and the minimum pressure-phase difference curve is used to determine a second threshold for the working pressure range.

[0095] Figure 5 This is a schematic diagram of pressure-phase difference curves provided according to some embodiments of this application. For example... Figure 5 As shown, this includes the minimum phase difference curve and the maximum phase difference curve. Since the maximum phase difference is always π / 2 regardless of the pressure sampling value used, the maximum phase difference curve is a straight line.

[0096] The minimum phase difference can be calculated by taking the maximum and minimum phase differences from the sweep curve corresponding to each pressure sample value, and then using the minimum phase difference for subsequent calculations.

[0097] The pressure-phase difference minimum curve can be formed by connecting the data points of different pressure sampling values ​​and their corresponding phase difference minimum values ​​with the pressure sampling values ​​as the horizontal axis and the phase difference minimum values ​​of the sweep frequency curves for each pressure sampling value as the vertical axis. This curve intuitively shows the correlation between pressure changes and the phase difference minimum value, which helps to further analyze and determine the working pressure range.

[0098] The first threshold, or the lower limit of the working pressure range, means that the minimum pressure required for welding is set at this first threshold. This means that the working pressure cannot be lower than this value, otherwise the basic quality and effect of the welding cannot be guaranteed. It is one of the important boundary conditions for defining the working pressure range.

[0099] The second threshold, which is the upper limit of the working pressure range, is determined by analyzing and judging the minimum pressure-phase difference curve. Together with the first threshold, it defines the appropriate working pressure range for the digital ultrasonic welding machine, ensuring that welding within this range can achieve better welding quality and equipment operation.

[0100] This approach involves first compiling two sets of data: the pressure sampling values ​​and the corresponding minimum phase difference. Then, using plotting software, data analysis tools, or the curve plotting function built into the device, these data points are sequentially marked on a Cartesian coordinate system according to mathematical coordinate correspondences. These points are then connected by lines to form a pressure-minimum phase difference curve, which visually presents the changing pattern between the two and provides a visual basis for determining the working pressure range.

[0101] The determination of the second threshold can be achieved by analyzing the constructed pressure-phase difference minimum curve, such as observing the trend of the curve, finding specific turning points in the curve (such as points where the slope changes significantly), combining previous welding experience and the requirements of the phase difference and pressure relationship in relevant welding process standards, and comprehensively determining a suitable pressure value as the second threshold. This, together with the first threshold (the minimum pressure required for welding), determines the working pressure range of the digital ultrasonic welding machine, ensuring that the welding operation can be carried out within a reasonable pressure range.

[0102] In one embodiment, optionally, determining a second threshold for the operating pressure range using the pressure-phase difference minimum curve includes:

[0103] The pressure corresponding to the standard phase difference in the pressure-phase difference minimum curve is determined as the second threshold of the working pressure range; wherein, the standard phase difference is selected based on the control capability of the ultrasonic power supply.

[0104] The standard phase difference can be a specific phase difference value selected based on the control capability of the ultrasonic power supply itself. It serves as a reference standard to find the corresponding pressure value in the pressure-phase difference minimum curve, thereby determining the second threshold of the working pressure range. It reflects a relatively ideal welding-related phase difference state under this control capability.

[0105] The control capability of an ultrasonic power supply refers to its performance level and operational range in adjusting the output frequency, controlling the output power, and maintaining a stable electrical signal. For example, it can precisely control the frequency range and adjust the power range. These capabilities affect parameters such as phase difference during the welding process and are the basis for selecting a standard phase difference.

[0106] This solution involves finding the pressure value corresponding to the selected standard phase difference value within the pre-constructed pressure-phase difference minimum curve. Through data matching, coordinate positioning, and other methods, the solution accurately identifies the pressure value that meets the conditions. This pressure value is then defined and set as the second threshold of the working pressure range. Together with the previously mentioned first threshold, which uses the minimum pressure required for welding, this solution defines the complete working pressure range, providing an accurate pressure range limit for the actual welding operation of the digital ultrasonic welding machine.

[0107] This embodiment also provides a preferred implementation method.

[0108] First, the operating frequency under different pressures is determined. The steps include:

[0109] S1: Control the downward pressure of the welding head; before contacting the workpiece, the ultrasonic power supply starts frequency search.

[0110] S2: Control the welding head to continue to press down slowly, keep the ultrasonic power supply searching for frequency, and collect and record the pressure and ultrasonic power supply frequency at different times in real time;

[0111] S3: When the welding head pressure reaches the predetermined maximum pressure or the ultrasonic power supply frequency search alarm is triggered, stop the welding head pressing down and the generator frequency search, and complete the data recording.

[0112] S4: Generate a pressure-frequency relationship curve, based on the operating frequency range corresponding to the design parameters of the ultrasonic transducer and welding head used [f]. d1 ,f d2 The first pressure range [F1, F2] is obtained by considering the minimum pressure required for welding and the pressure-frequency curve, where F1 is the minimum pressure required for welding and F2 is the pressure at the frequency f. d2 The pressure value.

[0113] Next, multiple pressure locations within the pressure range [F1, F2] are selected for frequency sweeping, and the upper and lower limits of the phase difference obtained from each frequency sweep are recorded. The specific steps are as follows:

[0114] S5: Control the welding head to slowly press down until the pressure reaches F1, then start the ultrasonic generator to sweep the frequency. The sweep range is [f d1 ,f d2 Record the frequency sweep curve for this operation;

[0115] S6: Control the welding head to continue pressing down until the pressure increases by the pressure interval F compared to the previous pressure. d Restart the ultrasonic generator to perform a frequency sweep, with the sweep range being [f]. d1 ,f d2 Record the sweep frequency curve;

[0116] S7: Repeat the above steps and record the frequency sweep curve W for each cycle. n The frequency sweep curve is recorded as W until the current pressure reaches or exceeds F2. N .

[0117] After obtaining the above sweep frequency curve W1-W N Then, the curve data was analyzed, and the maximum and minimum phase difference values ​​in each frequency sweep curve were extracted to obtain the pressure-phase difference curve.

[0118] Based on the pressure-phase difference curves described above, select a pressure range [F] where the phase difference meets the requirements. s1 F s2 ]. Among them, F s1 =F1,F s2 The minimum phase difference curve corresponds to a pressure value with a phase difference of P2. P2 is selected based on the control capability of the ultrasonic power supply, and is generally no greater than -π / 4.

[0119] This solution combines the working modes of welding machine pressure control and digital ultrasonic power supply to automatically perform corresponding actions and data acquisition, obtaining relevant curves to help users understand the performance of the welding machine and avoid using inappropriate working parameters that may affect the welding effect.

[0120] Furthermore, some embodiments of this application also provide an electronic device. The electronic device can be various forms of digital computer, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, etc. The electronic device can also be various forms of mobile devices, such as personal digital assistants, cellular phones, smartphones, wearable devices, and other similar computing devices.

[0121] The electronic device includes: one or more processors; and a memory storing computer program instructions that, when executed, cause the processor to perform the steps of the methods provided in any one or more of the above embodiments. Figure 6 An exemplary structural diagram of the electronic device is disclosed. For example... Figure 6 As shown, the electronic device includes one or more processors 601, a memory 602, and interfaces for connecting the components, including high-speed interfaces and low-speed interfaces. The components are interconnected via different buses and can be mounted on a common motherboard or otherwise as required. The processors can process instructions executed within the electronic device, including instructions stored in or on memory to display graphical information of the GUI on an external input / output device (such as a display device coupled to the interface). In some other embodiments, multiple processors and / or multiple buses can be used with multiple memories and multiple memory modules, if desired. Similarly, multiple electronic devices can be connected, each providing some of the necessary operations (e.g., as a server array, a group of blade servers, or a multiprocessor system). The components, their connections and relationships, and their functions shown herein are merely examples and are not intended to limit the implementation of the present application described and / or claimed herein.

[0122] The electronic device may further include an input device 603 and an output device 604. The processor 601, memory 602, input device 603, and output device 604 can be connected via a bus or other means. Figure 6 The bus connection is taken as an example.

[0123] Input device 603 can receive input digital or character information, and generate key signal inputs related to user settings and function control of the electronic device, such as touch screen, keypad, mouse, trackpad, touchpad, joystick, one or more mouse buttons, trackball, joystick, etc. Output device 604 may include display device, auxiliary lighting device (e.g., LED), and haptic feedback device (e.g., vibration motor). The display device may include, but is not limited to, liquid crystal display (LCD), light-emitting diode (LED) display, and plasma display. In some embodiments, the display device may be a touch screen.

[0124] To provide interaction with the user, the electronic device can be a computer. The computer has: a display device for displaying information to the user (e.g., a cathode-ray tube (CRT) or an LCD monitor); and a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the computer. Other types of devices can also be used to provide interaction with the user; for example, the feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form (including sound input, voice input, or tactile input).

[0125] In this embodiment, a computer-readable medium stores a computer program / instructions that, when executed by a processor, implement the steps of the methods provided in any one or more of the above embodiments. This computer-readable medium may be included in the electronic device described in the above embodiments; or it may exist independently and not assembled into that device. The aforementioned computer-readable medium carries one or more computer-readable instructions.

[0126] The memory 602 can serve as a non-transitory computer-readable storage medium, used to store non-transitory software programs, non-transitory computer-executable programs, and modules. The processor 601 executes various server functions and data processing by running the non-transitory software programs, instructions, and modules stored in the memory 602, thereby implementing the program instructions / modules corresponding to the methods provided in any one or more of the embodiments described above in this application.

[0127] The memory 602 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function; the data storage area may store data created based on the use of the electronic device. Furthermore, the memory 602 may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, the memory 602 may optionally include memory remotely located relative to the processor 601, and these remote memories can be connected to the electronic device via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0128] It should be noted that the computer-readable medium described in this application can be a computer-readable signal medium or a computer-readable storage medium, or any combination thereof. A computer-readable medium can be, for example,—but not limited to—an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples of a computer-readable storage medium may include, but are not limited to: an electrical connection having one or more wires, a portable computer disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM, or flash memory), optical fiber, portable compact disc read-only memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof. In this application, a computer-readable medium can be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, apparatus, or device.

[0129] Computer-readable media include both permanent and non-permanent, removable and non-removable media, which can store information by any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change random-access memory (PRAM), static random-access memory (SRAM), dynamic random-access memory (DRAM), other types of random-access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, read-only optical disc (CD-ROM), digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transfer medium that can be used to store information accessible by a computing device.

[0130] Computer program code for performing the operations of this application can be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as the "C" language or similar programming languages. The program code can be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network—including a local area network (LAN) or a wide area network (WAN)—or can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0131] In the above embodiments, all or part of the implementation can be achieved through software, hardware, firmware, or any combination thereof. For example, it can be implemented using an Application-Specific Integrated Circuit (ASIC), a general-purpose computer, or any other similar hardware device. In some embodiments, the software program of this application can be executed by a processor to implement the above steps or functions. Similarly, the software program of this application (including related data structures) can be stored in a computer-readable recording medium, such as RAM memory, magnetic or optical drives, floppy disks, and similar devices. In addition, some steps or functions of this application can be implemented in hardware, for example, as circuitry that cooperates with a processor to perform the various steps or functions.

[0132] The computer program product provided in this application includes one or more computer programs / instructions. When executed by a processor, these computer programs / instructions generate, in whole or in part, the processes or functions described in this application. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions may be transmitted from one website, computer, server, or data center to another via wired (e.g., coaxial cable, optical fiber, Digital Subscriber Line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium may be any available medium accessible to a computer or a data storage device such as a server or data center that integrates one or more available media. The available medium may be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., solid-state drive, SSD, etc.).

[0133] The flowcharts or block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of devices, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using a dedicated hardware-specific system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0134] The scope of this application is defined by the appended claims rather than the foregoing description, and is therefore intended to encompass all variations falling within the meaning and scope of equivalents of the claims. No reference numerals in the claims should be construed as limiting the scope of the claims. Furthermore, it is clear that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units or devices recited in a device claim may also be implemented by a single unit or device in software or hardware. Terms such as "first," "second," etc., are used only for distinguishing descriptions and do not indicate any particular order, nor should they be construed as indicating or implying relative importance.

[0135] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily made by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims, and the above embodiments should be regarded as exemplary and non-limiting.

Claims

1. A method for determining the working pressure range of a digital ultrasonic welding machine, characterized in that, The method includes: Before contacting the workpiece, the welding head is controlled to press down, and the ultrasonic power supply frequency search is started to collect the pressure of the welding head and the frequency of the ultrasonic power supply at different times. Based on the pressure of the welding head and the frequency of the ultrasonic power supply at different times, a pressure-frequency relationship curve is generated. The first pressure range is obtained based on the minimum pressure required for welding and the maximum pressure determined according to a predetermined operating frequency range; Within the first pressure range, at least two pressure sample values ​​are obtained by sampling according to the preset sampling rules; Frequency sweep is performed at each pressure sampling value to obtain the frequency sweep curve corresponding to each pressure sampling value; Obtain the phase difference of the sweep curve corresponding to each pressure sample value; The working pressure range of the digital ultrasonic welding machine is determined based on the phase difference.

2. The method according to claim 1, characterized in that, The operating pressure range of the digital ultrasonic welding machine is determined based on the phase difference, including: Obtain the minimum phase difference of the sweep curve corresponding to each pressure sample value; Construct a pressure-phase difference minimum curve; The minimum pressure required for welding is used as a first threshold for the working pressure range, and the minimum pressure-phase difference curve is used to determine a second threshold for the working pressure range.

3. The method according to claim 2, characterized in that, Determining a second threshold for the operating pressure range using the minimum pressure-phase difference curve includes: The pressure corresponding to the standard phase difference in the pressure-phase difference minimum curve is determined as the second threshold of the working pressure range; wherein, the standard phase difference is selected based on the control capability of the ultrasonic power supply.

4. The method according to claim 1, characterized in that, After controlling the downward pressure of the welding head before contacting the workpiece and starting the ultrasonic power supply frequency search, the method further includes: When the preset termination condition is met, the welding head pressing down and the generator frequency search are stopped, and data recording is completed.

5. The method according to claim 4, characterized in that, The preset termination conditions include the welding head pressure reaching the predetermined maximum pressure, or the ultrasonic power supply frequency search alarm.

6. The method according to claim 1, characterized in that, The predetermined operating frequency range is determined based on the design parameters of the ultrasonic transducer and the welding head.

7. The method according to claim 1, characterized in that, Within the first pressure range, at least two pressure sample values ​​are obtained by sampling according to a preset sampling rule, including: Within the first pressure range, pressure sampling values ​​are obtained by increasing the preset pressure interval each time.

8. An electronic device, characterized in that, The electronic device includes: One or more processors; and A memory storing computer program instructions, which, when executed, cause the processor to perform the steps of the method as described in any one of claims 1 to 7.

9. A computer-readable medium having a computer program / instructions stored thereon, characterized in that, When the computer program / instructions are executed by the processor, they implement the steps of the method according to any one of claims 1 to 7.

10. A computer program product comprising a computer program / instructions, characterized in that, When the computer program / instructions are executed by the processor, they implement the steps of the method according to any one of claims 1 to 7.

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