Method and device for controlling ultrasonic welding strength and electronic equipment

Abstract

The invention discloses an ultrasonic welding strength control method and device and electronic equipment, and belongs to the technical field of semiconductor manufacturing. The method comprises the steps that a welding head is driven to apply pressure to a load terminal in the Z-axis direction, and the real-time pressure value applied to the load terminal is obtained in real time through a pressure sensor; judging whether the real-time pressure value is equal to a preset pressure value or not; if yes, acquiring a position value of a load terminal; after the position numerical value is obtained, the welding head continues to be driven to press the load terminal and the copper-clad ceramic substrate in the Z-axis direction, and ultrasonic waves are generated through the welding head so that the load terminal can be welded to the copper-clad ceramic substrate through the ultrasonic waves; in the process that the welding head continues to be driven to move in the Z-axis direction, downward moving position information of the load terminal is obtained in real time; whether the downward moving position is equal to the preset welding depth or not is judged; and if yes, stopping driving the welding head to move, and stopping generating the ultrasonic waves by the welding head. The technical effects of improving the bonding strength of the load terminal and the copper-clad ceramic substrate and improving the welding quality are achieved.

Description

Technical Field

[0001] This invention belongs to the field of semiconductor manufacturing technology, and specifically relates to a method, apparatus, and electronic device for controlling the strength of ultrasonic welding. Background Technology

[0002] In the manufacturing process of silicon carbide power modules, ultrasonic welding technology is widely used for connecting the load terminals to the copper-clad ceramic substrate. With the increasing demands for precision and high performance in electronic products, more stringent standards are being placed on the stability and consistency of ultrasonic welding quality. In existing technologies, ultrasonic welding primarily employs a time-controlled mode, fixing the ultrasonic energy within a preset time frame for welding. However, in actual production, the surface conditions of the load terminals and the copper-clad ceramic substrate are not entirely consistent, and the degree of warpage also varies. This results in inconsistent bonding strength between the load terminals and the copper-clad ceramic substrate under the same welding time, leading to significant fluctuations in welding quality and making it difficult to meet the demands of high-precision, high-quality production.

[0003] Therefore, it is necessary to provide a new technical solution to solve the above-mentioned technical problems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is the low bonding strength and poor welding quality between the load terminal and the copper-clad ceramic substrate.

[0005] To address the aforementioned technical problems, this invention provides a method for controlling the strength of ultrasonic welding. The method includes driving a welding head to apply pressure along the Z-axis towards a load terminal to press the load terminal against a copper-clad ceramic substrate, and acquiring real-time pressure values ​​applied to the load terminal using a pressure sensor; comparing the real-time pressure value with a preset pressure value to determine if the real-time pressure value is equal to the preset pressure value; if so, acquiring the position value of the load terminal; after acquiring the position value, continuing to drive the welding head along the Z-axis to press the load terminal against the copper-clad ceramic substrate, and generating ultrasonic waves through the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate; while continuing to drive the welding head along the Z-axis, acquiring real-time downward displacement information of the load terminal; based on a preset welding depth and the acquired downward displacement position, determining if the downward displacement position is equal to the preset welding depth; if so, stopping the movement of the welding head and stopping the generation of ultrasonic waves.

[0006] Optionally, the method further includes placing the copper-clad ceramic substrate on a carrier and placing the load terminal on the copper-clad ceramic substrate.

[0007] Optionally, the drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and the real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. This includes driving the welding head along the Z-axis direction to contact the load terminal with the copper-clad ceramic substrate; continuing to drive the welding head downward along the Z-axis direction until the gap between the load terminal and the copper-clad ceramic substrate is eliminated, and the real-time pressure value applied to the load terminal is detected in real time by the pressure sensor.

[0008] Optionally, continuing to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis includes maintaining a preset pressure value to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis.

[0009] Optionally, the real-time acquisition of the downward position of the load terminal includes real-time acquisition of the current position information of the welding head; and calculation of the downward position information based on the difference between the current position information of the welding head and the position value.

[0010] Optionally, the downward position is obtained according to ΔH1 = |H2 - H1|, where ΔH1 is the downward position information and H2 is the current position information.

[0011] Optionally, the preset welding depth is less than the height of the load terminal along the Z-axis.

[0012] According to another aspect of the present invention, the present invention also provides an apparatus for controlling the ultrasonic welding strength, comprising a driver, a lead screw connected to the driver, a pressure sensor connected to the lead screw, a welding head connected to the pressure sensor, and a controller. The driver drives the lead screw to move the welding head connected to the pressure sensor along the Z-axis direction. The controller is communicatively connected to the driver, the welding head, and the pressure sensor, and is configured to perform the following steps: driving the welding head to apply pressure to a load terminal along the Z-axis direction to press the load terminal against a copper-clad ceramic substrate, and acquiring the real-time pressure value applied to the load terminal in real time through the pressure sensor; and controlling the real-time pressure... The force value is compared with a preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value; if so, the position value of the load terminal is obtained; after obtaining the position value, the welding head continues to be driven along the Z-axis to press the load terminal and the copper-clad ceramic substrate together, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate; while continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is obtained in real time; based on the preset welding depth and the obtained downward position, it is determined whether the downward position is equal to the preset welding depth; if so, the movement of the welding head is stopped, and the welding head stops generating ultrasonic waves.

[0013] Optionally, the device further includes a carrier having a bearing surface for placing the copper-clad ceramic substrate, the bearing surface being perpendicular to the Z-axis direction.

[0014] According to another aspect of the present invention, the present invention also provides an electronic device for controlling ultrasonic welding strength, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, it performs the following steps: driving a welding head to apply pressure to a load terminal along the Z-axis direction to press the load terminal against a copper-clad ceramic substrate, and acquiring a real-time pressure value applied to the load terminal in real time via a pressure sensor; comparing the real-time pressure value with a preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value; if so, acquiring the position value of the load terminal; after acquiring the position value, continuing to drive the welding head along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and generating ultrasonic waves through the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate; while continuing to drive the welding head to move along the Z-axis direction, acquiring real-time downward displacement information of the load terminal; based on a preset welding depth and the acquired downward displacement position, determining whether the downward displacement position is equal to the preset welding depth; if so, stopping the movement of the welding head and stopping the generation of ultrasonic waves.

[0015] Beneficial effects:

[0016] This invention provides a method for controlling the strength of ultrasonic welding. The method involves driving a welding head to apply pressure along the Z-axis towards a load terminal, pressing the load terminal against a copper-clad ceramic substrate. A pressure sensor continuously monitors the real-time pressure applied to the load terminal. The real-time pressure value is compared with a preset pressure value to determine if they are equal. If they are, the position of the load terminal is determined. After obtaining the position value, the welding head continues to press the load terminal against the copper-clad ceramic substrate along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal onto the copper-clad ceramic substrate. During the continued movement of the welding head along the Z-axis, the downward position information of the load terminal is continuously monitored. Based on a preset welding depth and the obtained downward position, it is determined whether the downward position equals a preset welding depth. If so, the movement of the welding head is stopped, and the ultrasonic waves are no longer generated. This comparison of the real-time pressure value and the preset pressure value ensures close contact between the surface of the load terminal and the surface of the copper-clad ceramic substrate, providing a reference point for subsequent welding depth control. Then, while initiating ultrasonic welding, the load terminal is gradually pressed into the copper-clad ceramic substrate, causing deformation of the load terminal. During the ultrasonic welding stage, the acquired downward displacement information of the load terminal is compared with the preset welding depth, and the downward displacement of the load terminal is monitored in real time. When the load terminal reaches the preset depth in the copper-clad ceramic substrate, the pressure on the load terminal is immediately stopped, achieving accurate control of the welding depth. This avoids insufficient pressure on the load terminal leading to a weak weld, or excessive pressure damaging the substrate, as well as depth deviation affecting the bonding strength. Therefore, it achieves the technical effect of improving the bonding strength between the load terminal and the copper-clad ceramic substrate and enhancing welding quality. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A flowchart illustrating a method for controlling the strength of ultrasonic welding according to an embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the structure of an ultrasonic welding strength control device provided in an embodiment of the present invention.

[0020] Figure 3This is a schematic diagram of the load terminal in an ultrasonic welding strength control device provided in an embodiment of the present invention.

[0021] Figure 4 This is a schematic diagram of the first state of the load terminal in an ultrasonic welding strength control device provided in an embodiment of the present invention.

[0022] Figure 5 This is a schematic diagram of the downward displacement position of the load terminal in an ultrasonic welding strength control device provided in an embodiment of the present invention.

[0023] Figure 6 The diagram shows the structure of the controller, driver, pressure sensor, and welding head in an ultrasonic welding strength control device provided in an embodiment of the present invention.

[0024] Figure 7 This is a structural diagram of an electronic device for controlling ultrasonic welding strength, provided as an embodiment of the present invention. Detailed Implementation

[0025] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0026] To enable those skilled in the art to better understand the solutions of this application, 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 a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0027] In the embodiments of this application, "at least one" refers to one or more; "multiple" refers to two or more. In the description of this application, the terms "first," "second," "third," etc., are used only for the purpose of distinguishing descriptions and should not be construed as indicating or implying relative importance, nor should they be construed as indicating or implying order.

[0028] In this specification, references such as "one embodiment" or "some embodiments" mean that one or more embodiments of this application include the specific features, structures, or characteristics described in connection with that embodiment. Therefore, the terms "comprising," "including," "having," and variations thereof in this specification all mean "including but not limited to," unless otherwise specifically emphasized. It should be noted that in the embodiments of this application, "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone.

[0029] It should be noted that, in the embodiments of the present invention, when a component is referred to as being "fixed to" another component, it can be directly on the other component or an intervening component may be present. When a component is considered to be "connected to" another component, it can be directly connected to the other component or an intervening component may be present simultaneously. When a component is considered to be "set on" another component, it can be directly set on the other component or an intervening component may be present simultaneously. Furthermore, in the embodiments of this application, "connection" can also be understood as an electrical connection; the connection between two electrical components can be a direct or indirect connection between the two electrical components. For example, the connection between A and B can be a direct connection between A and B, or an indirect connection between A and B through one or more other electrical components. The terms "vertical," "horizontal," "left," "right," and similar expressions used in the embodiments of the present invention are for illustrative purposes only and are not intended to limit the present invention.

[0030] Furthermore, in embodiments of the present invention, it should be understood that the at least one controller disclosed herein may include various microprocessors, integrated circuits, storage devices (e.g., flash memory, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variations), and software that cooperates to perform the operations disclosed herein. In addition, the at least one controller disclosed herein utilizes one or more microprocessors to execute a computer program contained in a non-transitory computer-readable medium, the computer program being programmed to perform any number of the disclosed functions. Furthermore, the controller provided herein includes a housing and various numbers of microprocessors, integrated circuits, and storage devices (e.g., flash memory, random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM)) located within the housing. The disclosed controller also includes hardware-based inputs and outputs for receiving data from and sending data to other hardware-based devices discussed herein, respectively.

[0031] Please see Figure 1 , Figure 1 This is a flowchart illustrating a method for controlling ultrasonic welding strength according to an embodiment of the present invention. Embodiment 1 of the present invention provides a method for controlling ultrasonic welding strength, comprising the following steps:

[0032] Step S100: Drive the welding head to apply pressure to the load terminal along the Z-axis direction to press the load terminal and the copper-clad ceramic substrate together, and obtain the real-time pressure value applied to the load terminal in real time through the pressure sensor.

[0033] The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate. The real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. This includes driving the welding head along the Z-axis direction to contact the load terminal with the copper-clad ceramic substrate; continuing to drive the welding head downward along the Z-axis direction until the gap between the load terminal and the copper-clad ceramic substrate is eliminated; and the real-time pressure value applied to the load terminal is detected by the pressure sensor.

[0034] Specifically, the driver may include a servo motor, which drives the welding head downwards along the Z-axis until it contacts the load terminal. The driver continues to drive the welding head downwards until the physical gap between the load terminal and the copper-clad ceramic substrate is eliminated. During this process, a pressure sensor monitors the pressure applied to the load terminal in real time. The Z-axis direction can refer to... Figure 2 In the vertical direction shown, the real-time pressure value refers to the pressure applied to the load terminal by the welding head driven by the driver. The pressure value obtained after eliminating the gap can provide an initial reference for subsequent pressure control, ensuring complete contact between the load terminal and the substrate surface, laying the foundation for precise depth control. If a servo motor is connected to the lead screw described below, the servo motor drives the lead screw to rotate. A metal mounting base can be provided on the lead screw, which drives the metal mounting base to move up and down. A pressure sensor is mounted on the metal mounting base, and the welding head is connected to the pressure sensor. The pressure sensor can measure the pressure applied to the load terminal by the welding head. Additionally, the driver can also monitor the distance the welding head descends. For example, by monitoring the number of rotations of the driver, the distance the lead screw drives the welding head to descend can be measured, enabling real-time monitoring of the welding head's descent distance.

[0035] Step S200: Compare the real-time pressure value with the preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value;

[0036] Specifically, assuming the real-time pressure value is F1 and the preset pressure value is F2, the real-time pressure value fed back by the pressure sensor is compared with the preset pressure value in real time to determine whether F1 equals F2. The preset pressure value F2 can be set according to the yield strength of the load terminal material. When F1 = F2, it indicates that the load terminal is in the preset compression state. At this time, the contact stress at the interface between the load terminal and the copper-clad ceramic substrate reaches the threshold required for welding, which can trigger the position reference measurement.

[0037] Step S300: If yes, then obtain the position value of the load terminal;

[0038] Specifically, when F1 = F2 is determined in step S200 above, the Z-axis position value H1 of the load terminal is obtained. Alternatively, the current position of the welding head can be read using the encoder in the driver, and this position can be equated to the initial reference position of the load terminal vertex after gap elimination, or... Figure 2 As shown, H1 is used as the position value of the load terminal. H1 serves as the zero-point reference for calculating the welding depth, and all subsequent downward displacement can be measured with H1 as the origin. Alternatively, a laser rangefinder can be used to directly measure the surface position of the load terminal to reduce the cumulative error of the system.

[0039] Step S400: After obtaining the position value, continue to drive the welding head to press the load terminal and the copper-clad ceramic substrate along the Z-axis direction, and generate ultrasonic waves through the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate.

[0040] The step of continuing to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis includes maintaining a preset pressure value to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis.

[0041] Specifically, after obtaining position H1 in step S300 above, the welding head maintains a preset pressure F2 and continues to press down on the load terminal. Simultaneously, the ultrasonic generator is activated to generate ultrasonic vibrations of a certain frequency, achieving solid-state welding between the load terminal and the copper-clad ceramic substrate. The welding head can be equipped with an ultrasonic generator; activating the ultrasonic generator generates ultrasonic waves on the welding head for welding the load terminal and the copper-clad ceramic substrate. Continuous pressure under constant pressure causes the load terminal to undergo plastic deformation and embed into the copper-clad ceramic substrate. The ultrasonic vibration destroys the surface oxide layer and promotes atomic diffusion, forming a metallurgical bond.

[0042] Step S500: While continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is acquired in real time.

[0043] The real-time acquisition of the downward position of the load terminal includes acquiring the current position information of the welding head in real time; calculating the downward position information based on the difference between the current position information of the welding head and the position value. The downward position is obtained according to ΔH1 = |H2 - H1|, where ΔH1 is the downward position information and H2 is the current position information. The preset welding depth is less than the height of the load terminal along the Z-axis.

[0044] Specifically, please see Figure 5 As shown, Figure 5 This diagram illustrates the positions of the load terminals at H1 and H2. During the downward pressing of the welding head, the current position information H2 of the welding head is collected in real time. The real-time downward movement depth ΔH1 of the load terminal can be obtained according to the formula ΔH1=|H2–H1|, where ΔH1 is the difference between H1 and H2. The heights of H1 and H2 can also be the heights relative to the upper surface of the carrier. The preset welding depth is less than the original height of the load terminal, thus avoiding the complete embedding of the load terminal into the copper-clad ceramic substrate. ΔH1 can directly quantify the embedding depth of the load terminal into the substrate. Dynamic monitoring of ΔH1 ensures that the welding depth remains within a controllable range of plastic deformation.

[0045] Step S600: Based on the preset welding depth and the obtained downward position, determine whether the downward position is equal to the preset welding depth;

[0046] Specifically, by obtaining the downward position information of the load terminal in real time through the above step S500, the downward depth ΔH1 can be compared with the preset welding depth. Assuming the preset welding depth is ΔH, it is determined whether ΔH1 is equal to ΔH.

[0047] In step S700, if yes, then stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

[0048] Specifically, if step S600 determines that ΔH1 = ΔH, the driver movement is immediately stopped and the ultrasonic generator is turned off, terminating the welding process. This means that stopping pressure and ultrasonic vibration when the predetermined welding depth is reached avoids excessive pressure that could cause cracks in the copper-clad ceramic substrate, such as copper layer peeling, or weak welding.

[0049] An embodiment of the present invention provides a method for controlling the strength of ultrasonic welding, which further includes placing the copper-clad ceramic substrate on a carrier and placing the load terminal on the copper-clad ceramic substrate.

[0050] Specifically, the copper-clad ceramic substrate can be positioned onto a carrier manually or with a robotic arm, and the load terminals can be placed in a pre-defined soldering area on the copper-clad ceramic substrate. The carrier provides support for both the copper-clad ceramic substrate and the load terminals.

[0051] This invention provides a method for controlling the strength of ultrasonic welding. The method involves driving a welding head to apply pressure along the Z-axis towards a load terminal, pressing the load terminal against a copper-clad ceramic substrate. A pressure sensor continuously monitors the real-time pressure applied to the load terminal. The real-time pressure value is compared with a preset pressure value to determine if they are equal. If they are, the position of the load terminal is determined. After obtaining the position value, the welding head continues to press the load terminal against the copper-clad ceramic substrate along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal onto the copper-clad ceramic substrate. During the continued movement of the welding head along the Z-axis, the downward position information of the load terminal is continuously monitored. Based on a preset welding depth and the obtained downward position, it is determined whether the downward position equals a preset welding depth. If so, the movement of the welding head is stopped, and the ultrasonic waves are no longer generated. This comparison of the real-time pressure value and the preset pressure value ensures close contact between the surface of the load terminal and the surface of the copper-clad ceramic substrate, providing a reference point for subsequent welding depth control. Then, while initiating ultrasonic welding, the load terminal is gradually pressed into the copper-clad ceramic substrate, causing deformation of the load terminal. During the ultrasonic welding stage, the acquired downward displacement information of the load terminal is compared with the preset welding depth, and the downward displacement of the load terminal is monitored in real time. When the load terminal reaches the preset depth in the copper-clad ceramic substrate, the pressure on the load terminal is immediately stopped, achieving accurate control of the welding depth. This avoids insufficient pressure on the load terminal leading to a weak weld, or excessive pressure damaging the substrate, as well as depth deviation affecting the bonding strength. Therefore, it achieves the technical effect of improving the bonding strength between the load terminal and the copper-clad ceramic substrate and enhancing welding quality.

[0052] To provide a detailed explanation of the ultrasonic welding strength control device provided by the present invention, the above embodiment 1 describes a method for ultrasonic welding strength control in detail. Based on the same inventive concept, this application also provides an ultrasonic welding strength control device, as detailed in embodiment 2.

[0053] Please see Figures 2 to 6 . Figure 2 This is a schematic diagram of the structure of an ultrasonic welding strength control device provided in an embodiment of the present invention. Figure 3 This is a schematic diagram of the load terminal structure in an ultrasonic welding strength control device provided in an embodiment of the present invention. Figure 4 This is a schematic diagram of the first state of the load terminal in an ultrasonic welding strength control device provided in an embodiment of the present invention. Figure 5 This is a schematic diagram of the downward displacement position of the load terminal in an ultrasonic welding strength control device provided in an embodiment of the present invention. Figure 6This is a structural block diagram of the controller, driver, pressure sensor, and welding head in an ultrasonic welding strength control device provided by an embodiment of the present invention. Embodiment two of the present invention provides an ultrasonic welding strength control device, including a driver, a lead screw, a pressure sensor, a welding head, and a controller. The lead screw is connected to the driver, the pressure sensor is connected to the lead screw, and the welding head is connected to the pressure sensor. The driver drives the lead screw to move the welding head connected to the pressure sensor along the Z-axis. The controller is communicatively connected to the driver, the welding head, and the pressure sensor. The controller is configured to perform the following steps: drive the welding head to apply pressure to the load terminal along the Z-axis to press the load terminal against the copper-clad ceramic substrate, and acquire the real-time pressure value applied to the load terminal using the pressure sensor; compare the real-time pressure value with a preset pressure value to determine if the real-time pressure value is equal to the preset pressure value; if so, acquire the position value of the load terminal; after acquiring the position value, continue driving the welding head along the Z-axis to press the load terminal against the copper-clad ceramic substrate, and generate ultrasonic waves through the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate; while continuing to drive the welding head to move along the Z-axis, acquire the downward position information of the load terminal in real time; based on a preset welding depth and the acquired downward position, determine if the downward position is equal to the preset welding depth; if so, stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

[0054] The lead screw can be a ball screw, and the pressure sensor can be connected to both the lead screw and the welding head, or the pressure sensor can be rigidly connected to the welding head via bolts. The pressure sensor acquires the pressure applied to the load terminal in real time. Vacuum adsorption holes can also be provided on the carrier surface to adsorb and limit the copper-clad ceramic substrate. The controller establishes communication connections with the driver, welding head, and pressure sensor, and can perform the following operations: controlling the driver to drive the welding head downwards along the Z-axis via the lead screw, pressing the load terminal against the copper-clad ceramic substrate, and simultaneously acquiring the real-time pressure value through the pressure sensor. The real-time pressure value is then compared with a preset pressure value to determine if they are equal. If the pressures are equal, the Z-axis position value of the load terminal is obtained. While maintaining the preset pressure value, the welding head is driven to continue pressing downwards, simultaneously triggering the welding head to generate ultrasonic waves, achieving welding between the load terminal and the substrate. Then, the difference between the current position and the initial position of the welding head is calculated in real time to obtain the downward displacement depth of the load terminal. When the downward displacement depth equals the preset welding depth, the movement of the welding head is stopped and the ultrasonic output is turned off.

[0055] Embodiment 2 of the present invention provides an ultrasonic welding strength control device, which further includes a carrier. The carrier is provided with a bearing surface for placing the copper-clad ceramic substrate, and the bearing surface is perpendicular to the Z-axis direction.

[0056] Specifically, the bearing surface, serving as the sole mounting reference for the copper-clad ceramic substrate, ensures that the plane of the substrate is orthogonal to the axis of motion of the soldering head (Z-axis). This eliminates uneven pressure distribution caused by the tilt of the substrate, ensuring that the direction of pressure applied by the soldering head is always perpendicular to the surface of the substrate, thus preventing lateral force from causing displacement of the load terminals. Simultaneously, when the substrate is perpendicular to the Z-axis, ultrasonic vibration energy is transmitted along the normal direction, improving energy transfer efficiency and preventing vibration energy reflection from causing amplitude attenuation of the soldering head.

[0057] This invention provides a device for controlling the strength of ultrasonic welding. A lead screw is connected to a driver, a pressure sensor is connected to the lead screw, and a welding head is connected to the pressure sensor. The driver drives the lead screw to move the welding head connected to the pressure sensor along the Z-axis. The controller is communicatively connected to the driver, welding head, and pressure sensor. The controller is configured to perform the following steps: drive the welding head to apply pressure along the Z-axis towards the load terminal to press the load terminal against the copper-clad ceramic substrate, and acquire the real-time pressure value applied to the load terminal via the pressure sensor; compare the real-time pressure value with a preset pressure value to determine if the real-time pressure value equals the preset pressure value; if so, acquire the position value of the load terminal; after acquiring the position value, continue driving the welding head along the Z-axis to press the load terminal against the copper-clad ceramic substrate, and generate ultrasonic waves through the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate; during the continued movement of the welding head along the Z-axis, acquire the downward position information of the load terminal in real time; based on a preset welding depth and the acquired downward position, determine if the downward position equals the preset welding depth; if so, stop driving the welding head to move, and the welding head stops generating ultrasonic waves. In this way, by comparing the real-time pressure value with the preset pressure value, the surface of the load terminal and the surface of the copper-clad ceramic substrate are tightly bonded together, providing a reference point for subsequent welding depth control. Then, while initiating ultrasonic welding, the load terminal is gradually pressed into the copper-clad ceramic substrate, causing deformation of the load terminal. During the ultrasonic welding stage, the acquired downward displacement information of the load terminal is compared with the preset welding depth, and the downward displacement of the load terminal is monitored in real time. When the load terminal reaches the preset depth in the copper-clad ceramic substrate, the pressure on the load terminal is immediately stopped, achieving accurate control of the welding depth. This avoids insufficient pressure on the load terminal leading to a weak weld, or excessive pressure damaging the substrate, as well as depth deviation affecting the bonding strength. Therefore, it achieves the technical effect of improving the bonding strength between the load terminal and the copper-clad ceramic substrate and enhancing welding quality.

[0058] To provide a detailed explanation of the electronic device for controlling ultrasonic welding strength provided by the present invention, the above embodiment 1 describes a method for controlling ultrasonic welding strength in detail. Based on the same inventive concept, this application also provides an electronic device for controlling ultrasonic welding strength, as detailed in embodiment 3.

[0059] Please see Figure 7 . Figure 7 This is a structural diagram of an electronic device for controlling ultrasonic welding strength according to an embodiment of the present invention. Embodiment 3 of the present invention provides an electronic device for controlling ultrasonic welding strength, including a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor 320. When the processor 320 executes the program, it performs the following steps:

[0060] The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and the real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor.

[0061] Compare the real-time pressure value with the preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value;

[0062] If so, then obtain the position value of the load terminal;

[0063] After obtaining the position value, the welding head is driven to press the load terminal and the copper-clad ceramic substrate together along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate.

[0064] While continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is acquired in real time;

[0065] Based on the preset welding depth and the obtained downward position, determine whether the downward position is equal to the preset welding depth;

[0066] If so, then stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

[0067] This invention provides an electronic device for controlling the intensity of ultrasonic welding. It drives a welding head to apply pressure along the Z-axis towards a load terminal, pressing the load terminal against a copper-clad ceramic substrate. A pressure sensor continuously monitors the real-time pressure applied to the load terminal. The real-time pressure is compared with a preset pressure value to determine if it equals the preset pressure value. If so, the position of the load terminal is determined. After obtaining the position value, the welding head continues to press the load terminal against the copper-clad ceramic substrate along the Z-axis, generating ultrasonic waves to ultrasonically weld the load terminal to the copper-clad ceramic substrate. During the continued movement of the welding head along the Z-axis, the downward position information of the load terminal is continuously monitored. Based on a preset welding depth and the obtained downward position, it is determined whether the downward position equals the preset welding depth. If so, the movement of the welding head is stopped, and the ultrasonic waves are no longer generated. This comparison of the real-time pressure value and the preset pressure value ensures close contact between the surface of the load terminal and the surface of the copper-clad ceramic substrate, providing a reference point for subsequent welding depth control. Then, while initiating ultrasonic welding, the load terminal is gradually pressed into the copper-clad ceramic substrate, causing deformation of the load terminal. During the ultrasonic welding stage, the acquired downward displacement information of the load terminal is compared with the preset welding depth, and the downward displacement of the load terminal is monitored in real time. When the load terminal reaches the preset depth in the copper-clad ceramic substrate, the pressure on the load terminal is immediately stopped, achieving accurate control of the welding depth. This avoids insufficient pressure on the load terminal leading to a weak weld, or excessive pressure damaging the substrate, as well as depth deviation affecting the bonding strength. Therefore, it achieves the technical effect of improving the bonding strength between the load terminal and the copper-clad ceramic substrate and enhancing welding quality.

[0068] In some embodiments, the apparatus provided in this disclosure may also have functions or included modules that can be used to perform the methods described in the above method embodiments. The specific implementation can be referred to the description of the above method embodiments, and for the sake of brevity, it will not be repeated here.

[0069] The description of the various embodiments above tends to emphasize the differences between the various embodiments. The similarities or similarities between them can be referred to, and for the sake of brevity, they will not be repeated here.

[0070] In the several embodiments provided in this application, it should be understood that the disclosed methods and apparatus can be implemented in other ways. For example, the apparatus implementations described above are merely illustrative. For instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the mutual coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection of devices or units may be electrical, mechanical, or other forms.

[0071] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0072] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) or processor to execute all or part of the steps of the methods of various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0073] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for controlling the strength of ultrasonic welding, characterized in that, The method includes The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and the real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. Compare the real-time pressure value with the preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value; If so, then obtain the position value of the load terminal; After obtaining the position value, the welding head is driven to press the load terminal and the copper-clad ceramic substrate together along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate. While continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is acquired in real time; Based on the preset welding depth and the obtained downward position, determine whether the downward position is equal to the preset welding depth; If so, then stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

2. The method for controlling ultrasonic welding strength according to claim 1, characterized in that, The method further includes placing the copper-clad ceramic substrate on a carrier and placing the load terminal on the copper-clad ceramic substrate.

3. The method for controlling ultrasonic welding strength according to claim 1, characterized in that, The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate. The real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. This includes driving the welding head along the Z-axis direction to contact the load terminal with the copper-clad ceramic substrate; continuing to drive the welding head downward along the Z-axis direction until the gap between the load terminal and the copper-clad ceramic substrate is eliminated; and the real-time pressure value applied to the load terminal is detected by the pressure sensor.

4. The method for controlling ultrasonic welding strength according to claim 1, characterized in that, The step of continuing to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis includes maintaining a preset pressure value to drive the welding head to press the load terminal and the copper-clad ceramic substrate together along the Z-axis.

5. The method for controlling ultrasonic welding strength according to claim 1, characterized in that, The real-time acquisition of the downward position of the load terminal includes real-time acquisition of the current position information of the welding head; and calculation of the downward position information based on the difference between the current position information of the welding head and the position value.

6. The method for controlling ultrasonic welding strength according to claim 5, characterized in that, The downward position is obtained based on ΔH1 = |H2 - H1|, where ΔH1 is the downward position information and H2 is the current position information.

7. The method for controlling ultrasonic welding strength according to claim 6, characterized in that, The preset welding depth is less than the height of the load terminal along the Z-axis.

8. A device for controlling the strength of ultrasonic welding, characterized in that, The device includes a driver, a lead screw connected to the driver, a pressure sensor connected to the lead screw, a welding head connected to the pressure sensor, and a controller. The driver drives the lead screw to move the welding head connected to the pressure sensor along the Z-axis. The controller is communicatively connected to the driver, the welding head, and the pressure sensor, and is configured to perform the following steps: The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and the real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. Compare the real-time pressure value with the preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value; If so, then obtain the position value of the load terminal; After obtaining the position value, the welding head is driven to press the load terminal and the copper-clad ceramic substrate together along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate. While continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is acquired in real time; Based on the preset welding depth and the obtained downward position, determine whether the downward position is equal to the preset welding depth; If so, then stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

9. The device for controlling ultrasonic welding strength according to claim 8, characterized in that, The device further includes a carrier having a support surface for placing the copper-clad ceramic substrate, the support surface being perpendicular to the Z-axis direction.

10. An electronic device for controlling the strength of ultrasonic welding, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it performs the following steps: The drive welding head applies pressure to the load terminal along the Z-axis direction to press the load terminal against the copper-clad ceramic substrate, and the real-time pressure value applied to the load terminal is obtained in real time by a pressure sensor. Compare the real-time pressure value with the preset pressure value to determine whether the real-time pressure value is equal to the preset pressure value; If so, then obtain the position value of the load terminal; After obtaining the position value, the welding head is driven to press the load terminal and the copper-clad ceramic substrate together along the Z-axis, and ultrasonic waves are generated by the welding head to ultrasonically weld the load terminal to the copper-clad ceramic substrate. While continuing to drive the welding head to move along the Z-axis, the downward position information of the load terminal is acquired in real time; Based on the preset welding depth and the obtained downward position, determine whether the downward position is equal to the preset welding depth; If so, then stop driving the welding head to move, and the welding head stops generating ultrasonic waves.

Images