Temperature control device for welding head and welding seat of ultrasonic welding

Abstract

The invention relates to a temperature control device for a welding head and a welding seat of ultrasonic welding, which comprises a heating unit arranged in the welding head and the welding seat and used for integrally heating the welding head and the welding seat; the temperature detection unit is used for detecting the temperature of the functional areas of the welding head and the welding seat; the data input end of the controller is connected with the temperature detection unit, and the control output end of the controller is connected with the heating unit; the controller uses feedback data of the temperature detection unit and a preset target temperature value in the controller as input, a control signal is generated through calculation of a PID control algorithm and sent to the heating unit, the heating unit adjusts the temperature according to the control signal, and therefore the welding head and the welding base work at the constant temperature. The welding consistency and stability can be improved, and the product quality of ultrasonic welding is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ultrasonic welding equipment, in particular to a temperature control device for an ultrasonic welding horn and anvil. BACKGROUND

[0002] In the ultrasonic welding process, the temperature of the horn and the anvil has a decisive influence on the welding quality. The existing structure of the ultrasonic welding horn and anvil lacks heating and temperature control devices, which can cause the following problems: (1) Insufficient welding strength: Heat is one of the important factors that promote the fusion of molecules between the welding materials. Without heating, the plastic deformation ability of the material is poor, and the intermolecular diffusion is insufficient, making it difficult to form a firm bond at the welding interface, thereby reducing the welding strength and causing the welded parts to crack, un-weld, and other problems during use; (2) Prolonged welding time: In order to achieve a certain welding effect, the ultrasonic welding time may need to be extended without heating the horn and anvil. However, long-term ultrasonic vibration can cause excessive fatigue damage to the welded parts and reduce production efficiency; (3) Surface damage of the welded parts: Due to the lack of heating assistance, the ultrasonic energy received by the surface of the welded parts is relatively concentrated, which can cause local overheating, wear, and even pits and scratches on the surface of the welded parts, affecting the appearance quality and dimensional accuracy of the welded parts; (4) Uneven welding: Without heating, the temperature distribution in the welding area is uneven, resulting in differences in welding effect at different parts, which can cause some areas to be well welded, while other areas may have insufficient welding strength or incomplete welding, affecting the overall performance of the welded parts. SUMMARY

[0003] One of the main purposes of the present application is to overcome at least one of the above-mentioned defects, and to provide a temperature control device for an ultrasonic welding horn and anvil, which can improve the consistency and stability of welding and improve the product quality of ultrasonic welding.

[0004] To achieve the above-mentioned purpose, the technical solution adopted by the present application is: The present application provides a temperature control device for an ultrasonic welding horn and anvil, which comprises: a heating unit arranged in the horn and the anvil for uniformly heating the horn and the anvil; a temperature detection unit for detecting the temperature of the functional area of the horn and the anvil; a controller connected to the temperature detection unit at the data input end and connected to the heating unit at the control output end; The controller uses the feedback data from the temperature detection unit and the preset target temperature value in the controller as inputs, calculates and generates a control signal through a PID control algorithm, and sends it to the heating unit. The heating unit adjusts the temperature according to the control signal so that the welding head and welding base work at a constant temperature.

[0005] According to one embodiment of the present invention, the welding head includes a housing, the housing having an internal cavity structure, and the heating element of the heating unit is a heating plate disposed in the cavity.

[0006] According to one embodiment of the present invention, the welding head adopts an integrated heating method, and the controller implements closed-loop feedback through a PID control algorithm to control the heating element so that the welding head operates at a constant temperature.

[0007] According to one embodiment of the present invention, the welding head includes a housing and a transducer oscillator, the heating unit is disposed near the welding base, and a heat insulation gasket is disposed between the transducer oscillator and the heating unit.

[0008] According to one embodiment of the present invention, the welding base is platform-shaped, and the heating body of the heating unit is a heating wire, which is coiled around the outside of the welding base.

[0009] According to one embodiment of the invention, the portion of the welding socket that comes into contact with other external components is covered with heat-insulating felt.

[0010] According to one embodiment of the present invention, a display unit is further included, which is connected to the data output terminal of the controller and is used to display the real-time temperature of the welding head and the welding socket, and the set target temperature value.

[0011] According to one embodiment of the present invention, the display unit is a touch display interface for human-computer interaction to set the target control value.

[0012] According to one embodiment of the present invention, the heating unit includes a heating body and a heating drive circuit. The heating drive circuit includes a power amplifier and a relay. The controller is connected to the power amplifier. The output terminal of the power amplifier is connected to the relay. The relay is disposed between the heating body and the power supply circuit. The control signal issued by the controller is a PWM signal. The power amplifier amplifies the PWM signal and controls the on / off state of the relay.

[0013] Compared with the prior art, the advantages and beneficial effects of the temperature control device for the ultrasonic welding head and welding seat of this invention patent application are as follows: This application, through the design of a heating structure at the welding head and welding base, combined with a closed-loop temperature control system, achieves precise closed-loop control of the working temperature of the welding head and welding base, resulting in optimized temperature uniformity in the welding area and improved product welding quality. Furthermore, the aforementioned structural optimization improves the thermal efficiency of the ultrasonic welding equipment and provides thermal insulation protection. The use of a touch display device enhances operational convenience and enables traceability of process parameters. Specifically, it offers the following advantages: 1. Ensure welding quality: By precisely controlling the temperature of the welding head and welding seat, the welding materials reach a good plastic state at a suitable temperature, promoting full fusion between molecules, thereby improving welding strength and welding consistency, reducing welding defects such as incomplete welds and porosity, and ensuring the stability of welding quality; 2. Protect welding materials and workpieces: Different welding materials have their specific temperature tolerance ranges. The temperature control system can prevent the material from overheating, burning, deforming or degrading due to excessive temperature, while avoiding excessively low temperature that would prevent good welding. This protects the welding materials and workpieces, allowing them to maintain their original performance and appearance. 3. Improve production efficiency: Reasonable temperature control helps to shorten welding time, reduce the number of adjustments and rework due to unsuitable temperature, make the welding process more efficient and smooth, and improve overall production efficiency; 4. Extend equipment lifespan: The temperature control system enables the welding head and welding base to operate within a suitable temperature range, avoiding accelerated wear and aging of the equipment due to overheating or excessive temperature fluctuations, thereby extending the service life of the ultrasonic welding equipment and reducing equipment maintenance costs. Attached Figure Description

[0014] The following sections will describe some specific embodiments of the invention in detail by way of example and not limitation, with reference to the accompanying drawings. The same reference numerals in the drawings denote the same or similar parts or portions. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings: Figure 1 This is a schematic diagram of the temperature control structure at the ultrasonic welding head weld base according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the working process of a temperature control device for an ultrasonic welding head and welding seat according to an embodiment of the present invention.

[0015] The annotations in the attached figures are explained as follows: 11. Heating element; 12. Heating wire; 13. Drive circuit; 2. Temperature detection unit; 3. Controller; 4. Welding head; 41. Housing; 42. Heat insulation gasket; 43. Transducer oscillator; 5. Welding base; 51. Heat insulation felt. Detailed Implementation

[0016] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0018] This embodiment describes a temperature control device for an ultrasonic welding head and welding socket, such as... Figure 1 As shown, it includes: A heating unit is provided in the welding head 4 and the welding base 5 for heating the welding head 4 and the welding base 5 as a whole; Temperature detection unit 2 is used to detect the temperature of the functional areas of the welding head 4 and the welding base 5. Temperature detection unit 2 can be a thermocouple, a thermistor or an infrared temperature sensor. Controller 3 has a data input terminal connected to the temperature detection unit 2 and a control output terminal connected to the heating unit; The working process is as follows: Figure 2 As shown, the controller 3 takes the feedback data from the temperature detection unit 2 and the preset target temperature value in the controller 3 as input, calculates and generates a control signal through a PID control algorithm and sends it to the heating unit. The heating unit adjusts the temperature according to the control signal so that the welding head 4 and the welding base 5 work at a constant temperature.

[0019] In one embodiment, the welding head 4 includes a housing 41 made of titanium alloy. The housing 41 has a cavity structure inside. The heating element of the heating unit is a heating element 11 (8mm in diameter, 500W in power) disposed in the cavity. The welding head 4 adopts an integrated heating method. The controller 3 achieves closed-loop feedback through a PID control algorithm to control the heating element 11 so that the welding head 4 operates at a constant temperature.

[0020] The temperature control circuit of the heating element 11 is implemented using a temperature controller, model STM32F407. The temperature controller contains a power amplifier and a relay. The controller 3 is connected to the power amplifier, and the output of the power amplifier is connected to the relay. The relay is located between the heating element and the power supply circuit. The control signal issued by the controller 3 is a PWM signal. The power amplifier amplifies the PWM signal and controls the relay to switch on and off, thereby controlling the power supply to the heating element 11 and achieving temperature control.

[0021] In addition, the welding head 4 includes a housing 41 and a transducer oscillator 43. The heating unit is located near the welding base 5. A heat insulation gasket 42 is provided between the transducer oscillator 43 and the heating unit. The heat insulation gasket 42 is supported by graphite.

[0022] In one embodiment, the welding base 5 is platform-shaped, and the heating body of the heating unit is a heating wire 12, which is coiled around the outside of the welding base 5.

[0023] The heating unit of the welding base 5 uses a heating resistance wire (i.e., heating wire 12) as the heating element, which is evenly wound around the outer periphery of the welding base 5 and fixed and isolated by a heat insulation felt made of high-temperature resistant insulating material to avoid short circuits and heat loss. For the heating unit of the welding head 4, a built-in heating element 11 is used, which is attached to the inside of the welding head near the welding end to quickly and accurately increase the temperature of the welding head.

[0024] In addition, K-type thermocouples are used as temperature sensors. Two thermocouples can be symmetrically installed on the welding base 5 near the heating wire 12 to ensure comprehensive monitoring of the temperature of the welding base 5; a miniature thermocouple is embedded at the welding working end of the welding head 4 to provide real-time feedback on the actual temperature of the welding head. The two thermocouples are connected to the controller 3 via high-temperature resistant wires to transmit temperature signals.

[0025] The heating wire 12 is provided with a driving circuit 13. The heating unit includes the heating wire 12 as the heating body and the heating driving circuit 13. The heating driving circuit 13 includes a power amplifier and a relay. The controller 3 is connected to the power amplifier. The output terminal of the power amplifier is connected to the relay. The relay is located between the heating body and the power supply circuit. The control signal issued by the controller 3 is a PWM signal. The power amplifier amplifies the PWM signal and controls the on / off state of the relay.

[0026] The part of the welding base 5 that comes into contact with other external components is covered with a 5mm thick heat insulation felt 51, and the measured ambient temperature rise decreased from 25℃ to 8℃.

[0027] In this embodiment, the PWM frequency is set to 1kHz, the relay (model JQC-3FF) switching cycle is 100ms, and the heating power adjustment accuracy reaches 10W.

[0028] In one embodiment, the temperature control device further includes a display unit connected to the data output terminal of the controller 3, used to display the real-time temperature of the welding head 4 and the welding base 5, and the set target temperature value. The display unit uses a touch display interface for human-computer interaction to set the target control value.

[0029] An example of an ultrasonic welding system with a temperature control device includes the following workflow during operation: 1. Operators set the target temperature (ideal temperature is 30~45℃) for the welding head and welding base through the human-machine interface. 2. After the system starts up, the temperature sensor collects the temperature of the welding head and welding base in real time and transmits the signal to the monitoring interface; 3. Based on the deviation between the current temperature and the set temperature, run the adaptive PID control algorithm to calculate the required heating power, and adjust the working state of the heating element through the drive circuit; 4. During the welding process, the system continuously monitors the temperature. If the temperature reaches the set value, it automatically maintains a constant temperature. If the temperature exceeds the upper limit of the set value, the air cooling system is used to cool down the equipment to ensure the safety of the equipment and the welding quality. 5. After welding is completed, the operator can shut down the system through the human-machine interface. At this time, the heating unit stops working and the system enters standby mode.

[0030] The specific beneficial effects of the temperature control device for the ultrasonic welding head and welding base in this embodiment are reflected in the following aspects: Improved welding quality: Temperature stability increased by 50%, and the standard deviation of welding strength decreased to below 0.8kN; Extended equipment lifespan: The thermal fatigue life of welding head 4 has been increased from 80,000 cycles to 150,000 cycles; Energy efficiency optimization: The thermal insulation design increases the thermal efficiency of welding socket 5 to 85%; Ease of use: The touch interface reduces parameter adjustment time by 70%.

[0031] In one embodiment, a protection circuit is also provided for the current, voltage, and sensors in the temperature control device, for example: 1. Overheat protection: Set an upper temperature threshold. When the temperature exceeds the set safe value, the heating power will be automatically cut off to prevent equipment damage and overheating of welding materials; 2. Overcurrent protection: An overcurrent protection device is installed to cut off the circuit in time when the current in the heating circuit exceeds the rated value, so as to avoid burning out the heating element or causing other safety accidents due to excessive current; 3. Sensor fault protection: It has a sensor fault detection function. When the temperature sensor fails, the system can promptly alarm and take corresponding protective measures, such as stopping heating or switching to a backup sensor. 4. Leakage protection: Ensure proper grounding of the electrical components of the temperature control system and install leakage protection devices to prevent electric shock to operators; 5. Power outage protection: Equipped with an uninterruptible power supply (UPS) or other power outage protection measures to save critical system parameters and data in the event of a sudden power outage, preventing data loss and equipment damage.

[0032] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A temperature control device for an ultrasonic welding head and welding seat, characterized in that, include: A heating unit is installed in the welding head and welding base to heat the welding head and welding base as a whole. A temperature detection unit is used to detect the temperature of the functional areas of the welding head and the welding base; The controller has a data input terminal connected to the temperature detection unit and a control output terminal connected to the heating unit. The controller uses the feedback data from the temperature detection unit and the preset target temperature value in the controller as inputs, calculates and generates a control signal through a PID control algorithm, and sends it to the heating unit. The heating unit adjusts the temperature according to the control signal so that the welding head and welding base work at a constant temperature.

2. The temperature control device for the ultrasonic welding head and welding seat according to claim 1, characterized in that, The welding head includes a housing with a cavity structure inside. The heating element of the heating unit is a heating plate, which is disposed in the cavity.

3. The temperature control device for the ultrasonic welding head and welding seat according to claim 2, characterized in that, The welding head uses an integrated heating element, and the controller uses a PID control algorithm to achieve closed-loop feedback, controlling the heating element to keep the welding head operating at a constant temperature.

4. The temperature control device for the ultrasonic welding head and welding seat according to any one of claims 1 to 3, characterized in that, The welding head includes a housing and a transducer oscillator. The heating unit is located near the welding base. A heat insulation gasket is provided between the transducer oscillator and the heating unit.

5. The temperature control device for the ultrasonic welding head and welding seat according to claim 1, characterized in that, The welding base is platform-shaped, and the heating body of the heating unit is a heating wire, which is coiled around the outside of the welding base.

6. The temperature control device for the ultrasonic welding head and welding seat according to claim 4, characterized in that, The portion of the welding socket that comes into contact with other external components is covered with heat-insulating felt.

7. The temperature control device for the ultrasonic welding head and welding seat according to claim 1, characterized in that, It also includes a display unit, which is connected to the data output terminal of the controller and is used to display the real-time temperature of the welding head and welding base and the set target temperature value.

8. The temperature control device for the ultrasonic welding head and welding seat according to claim 7, characterized in that, The display unit uses a touch display interface for human-computer interaction to set the target control value.

9. The temperature control device for the ultrasonic welding head and welding seat according to claim 1, characterized in that, The heating unit includes a heating body and a heating drive circuit. The heating drive circuit includes a power amplifier and a relay. The controller is connected to the power amplifier. The output terminal of the power amplifier is connected to the relay. The relay is located between the heating body and the power supply circuit. The control signal issued by the controller is a PWM signal. The power amplifier amplifies the PWM signal and controls the on / off state of the relay.

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