Method for determining condition-related information, e.g., wear-related information, regarding an ultrasonic welding device - Patents.com

Abstract

A method is described for determining status information for an ultrasonic welding apparatus (1). The status information specifies in detail information about a current state of at least one component (2) of the ultrasonic welding apparatus, which comprises as components a sonotrode (3), an anvil (5), a contact element (7) and / or a lateral slide (9) and a receiving chamber (11) defined by the components. The method includes the steps of (a) displacing a first component (33) and a second component (35) relative to each other, starting from an initial position in a first displacement direction (21) and detecting a first stop position at which a reaction force acting on the first component during the displacement reaches a predetermined maximum force, (b) displacing the first component and the second component in a second displacement direction (23) relative to each other to a changed position, (c) displacing the first component and the second component again relative to each other, starting from the changed position in the first displacement direction and detecting a second stop position at which a reaction force acting on the first component during the displacement reaches a predetermined maximum force, and (d) determining status information based on the detected first and second stop positions. The method can be used, for example, to detect wear indications, such as local recesses (36, 37), in one of the components.

Description

[Technical field]

[0001] The present invention relates to a method for determining status information, such as wear information, relating to an ultrasonic welding device. The present invention further relates to an ultrasonic welding device configured to perform the method, as well as a corresponding computer program product and machine readable media having the same stored thereon. [Background technology]

[0002] Ultrasonic welding can be used to join two components together in a mechanically secure and / or electrically conductive manner. For example, it may be necessary to join strands of a cable together in a mechanical and electrically conductive manner for various purposes. This makes it possible to produce wiring harnesses or cabling that can be used, for example, inside a vehicle, in a conductive manner to connect electrical consumables to each other, to an energy source, and / or to a control system.

[0003] Ultrasonic welding is a special form of friction welding in which the components to be welded are brought into face-to-face contact as joining partners and moved in contact with each other under low pressure and high frequency mechanical vibration. The vibration can be generated with the aid of a sonotrode assembly, where ultrasonic vibrations, typically having a frequency of 20 kHz to 50 kHz, are generated and transmitted to at least one of the joining partners. Plastic flow then allows the joining partners to penetrate or bond to each other near the faces without the need for melting the material of the joining partners. Thus, ultrasonic welding can be used to bond the joining partners together quickly and economically with low impact.

[0004] Ultrasonic welding can also be used in particular to weld metal joint partners, for example to weld and compress the individual conductors within a strand together, to join one or more strands to a contact element, and / or to weld metal sheets together, etc. For this purpose, the joint partners are generally inserted into a receiving chamber of an ultrasonic welding device and are then welded together between the sonotrode head and the anvil of the ultrasonically vibrating sonotrode. In this case, the receiving chamber can be defined on opposite sides by further components such as contact elements and lateral slides.

[0005] In ultrasonic welding, wear typically occurs on the components of the ultrasonic welding device. For example, wear on the surface of one of the components inside the ultrasonic welding device, caused by friction, can cause the originally provided texture to become rounded or otherwise altered, so that, for example, ultrasonic vibrations can be transmitted less efficiently to the joining partner. Wear can cause the welded joint to no longer meet certain requirements. The condition of the components of the ultrasonic welding device must therefore be monitored, among other things, in order to detect such wear in time. Intervention limits or wear limits can also be defined. This can be detected when such limits are reached and maintenance measures are initiated accordingly.

[0006] Other influences may also affect the operation mode and / or performance of the ultrasonic welding apparatus. For example, different types of components, i.e. differently designed sonotrodes, anvils, etc., may be used in the ultrasonic welding apparatus to suit different application requirements. With regard to the correct use of such component types, it may also be advantageous to monitor the status of the ultrasonic welding apparatus.

[0007] Conventionally, monitoring of ultrasonic welding machines is usually performed by machine operators or maintenance technicians, who are usually human. In this case, technically trained persons can detect, for example, excessive wear signs and thus prepare for, for example, maintenance of the ultrasonic welding machine and / or replacement of worn components. Such personnel can also identify whether the desired component type is used in the ultrasonic welding machine. However, such monitoring, which has to be performed by a person, requires very high personnel costs and / or is exposed to the risk of human error. Furthermore, detection of wear signs requires, for example, high qualifications on the part of the people involved. However, even experienced persons are usually not able to accurately distinguish the different stages of wear signs. This means that it is usually not possible to draw accurate qualified conclusions about the wear stages. Components exposed to wear are therefore often replaced early as a preventive measure. Alternatively, maintenance measures may be performed too late, so that welded joints produced with a partially worn ultrasonic welding machine no longer meet the given quality standards. In most cases, it is also hardly possible to describe the possible remaining useful life of the components. Summary of the Invention

[0008] Therefore, a method for determining status information of an ultrasonic welding apparatus may be needed, which may be used to eliminate or mitigate at least some of the above-mentioned deficiencies. In particular, a method may be needed that may be used to determine status information that allows conclusions to be drawn easily, reliably, accurately and / or cost-effectively about the wear of components and / or about the current configuration of the ultrasonic welding apparatus. In particular, it should preferably be possible to determine the status information automatically. Furthermore, an ultrasonic welding apparatus configured to perform such a method may be needed. Furthermore, a computer program product may be needed that may be used to instruct an ultrasonic welding apparatus to perform such a method, and a machine-readable medium on which such a computer program product is stored.

[0009] These requirements may be met by the subject matter of one of the independent claims. Advantageous embodiments are defined in the dependent claims and in the following description and illustrated in the figures.

[0010] A first aspect of the invention relates to a method for determining status information for an ultrasonic welding apparatus, where the status information specifies in detail information about a current status of at least one component of the ultrasonic welding apparatus. The ultrasonic welding apparatus comprises a plurality of components and a receiving chamber. The components comprise a sonotrode, and / or an anvil, and / or a contact element, and / or a lateral slide. The joining partner is accommodated in the receiving chamber. The receiving chamber is defined on a first side by a surface of a first one of the components, in particular the sonotrode, and on a second side opposite the first side by a surface of a second one of the components, in particular the anvil. The receiving chamber is optionally further defined on a third side by a surface of a third component, in particular the contact element, and on a fourth side opposite the third side by a surface of a fourth component, in particular the lateral slide. At least a first component and a second component opposite the first component are displaceable relative to each other in a first displacement direction towards each other and in a second displacement direction transverse to the first displacement direction. The first component and the second component are displaceable relative to each other in the first displacement direction such that a reaction force acting on the first component opposite to the first displacement direction reaches a predefined maximum force. The method comprises at least the following method steps, preferably in the specified order: (a) displacing a first component and a second component relative to each other starting from an initial position in a first displacement direction and detecting a first stop position at which a reaction force acting on the first component during the displacement reaches a predetermined maximum force; (b) displacing the first component and the second component relative to one another in a second displacement direction to a changed position; (c) displacing the first and second components relative to each other again in a first displacement direction, starting from the changed position, and detecting a second stop position in which the reaction force acting on the first component during the displacement reaches a predetermined maximum force; (d) determining status information based on the detected first stopping position and the second stopping position.

[0011] According to a second aspect of the present invention, an ultrasonic welding apparatus is described, comprising the structural and functional features already described for the first aspect and configured to perform or control a method according to an embodiment of the first aspect of the present invention.

[0012] According to a third aspect of the present invention there is described a computer program product comprising instructions which, when executed on a processor, instruct a processor to perform or control an embodiment of a method according to the first aspect of the present invention in an ultrasonic welding apparatus according to an embodiment of the second aspect of the present invention.

[0013] According to a fourth aspect of the present invention, a machine-readable medium having stored thereon a computer program product according to the third aspect of the present invention is described.

[0014] Briefly and roughly summarized, the basic idea of ​​the idea described herein can be seen in the fact that the displaceability of the components defining the receiving chamber of the ultrasonic welding device is used to be able to determine information about the current state, in particular the wear state, of these components. In this case, in each case, two of the components face each other in a surface defining the receiving chamber. At least two of the components can move towards and away from each other in a first direction, but also towards and away from each other in a second direction transverse thereto, preferably perpendicular thereto. In the first direction, the two components can be displaced until they are in direct or indirect rest contact with each other. The position at which such rest contact occurs and a predefined maximum force acts between the two components can be detected as a rest position. With regard to the second direction, by determining the rest positions for at least two, preferably a plurality of different positionings of the two components, it is possible to determine in the second direction a kind of height profile or surface profile that reflects the rest positions in the first direction for the different positionings of the two components relative to each other. From such a height or surface profile it is possible to determine information about the current state of the components, in particular about the current state of at least one of the facing surfaces of both components.

[0015] Possible details of embodiments of the methods proposed herein and ultrasonic welding apparatus configured for carrying them out are described below.

[0016] The ultrasonic welding device described herein is configured to weld together the joining partners contained in a receiving chamber by transmitting ultrasonic energy to the joining partners. In this case, the receiving chamber is surrounded by the components of the ultrasonic welding device from at least two opposite sides, preferably even from four sides in a ring shape. In this way, the components define a receiving chamber, typically of a rectangular parallelepiped shape, from at least two sides, preferably four sides. The joining partners can then be inserted into the receiving chamber, typically from the two sides that remain open.

[0017] In particular, at least one sonotrode and further components such as, in particular, the anvil, the contact element and the lateral slide act as components surrounding the receiving chamber. The sonotrode can be ultrasonically vibrated by a vibration generator. The surface of the sonotrode facing the receiving chamber can be textured, i.e. profiled, to effectively transmit the ultrasonic vibrations to the joining partner. Such a surface of the sonotrode defines the receiving chamber on a first side, according to the definition used in this specification. The anvil is generally arranged opposite the sonotrode. It serves as a counter-bearing for the joining partner on a second side of the receiving chamber, so that the joining partner can be clamped between the sonotrode and the anvil during the welding operation. The surface of the anvil facing the receiving chamber is also textured. Typically, the contact element and the lateral slide face each other perpendicularly to the direction in which the sonotrode and the anvil face each other, and by these surfaces define the receiving chamber on a third and fourth side, according to the definition. The term "contact element" should be interpreted broadly in this context and can refer to both the contact plate and the further lateral slide, towards which the first lateral slide can be moved to restrict from its side the joining partner contained in the receiving chamber, in such a way as to narrow the width of the receiving chamber. The surfaces of the contact elements and lateral slides facing the receiving chamber are typically smooth, but depending on the application can have a surface texture, such as corrugation.

[0018] The components that define the receiving chamber are displaceable relative to one another within a given degree of freedom. For example, typically the sonotrode and the anvil can be moved relative to one another towards one another or away from one another. In this case, the sonotrode can remain stationary and the anvil can be moved. Alternatively, the anvil can remain stationary and the sonotrode can be moved. Or even alternatively, both the sonotrode and the anvil can be moved. Furthermore, typically the contact element and the lateral slide can be moved relative to one another towards one another or away from one another. Again, one of the two components can remain stationary and the other can be displaced. Alternatively, both components can be displaced.

[0019] The displacement direction in which the two opposing components are displaced towards or away from each other is generally referred to herein as the first displacement direction. The first displacement direction for the displacement of the sonotrode relative to the anvil extends transversely, preferably perpendicularly, to the first displacement direction for the displacement of the contact element relative to the transverse slide. The receiving chamber can be narrowed or widened by displacing the opposing components in the respective first displacement direction.

[0020] In this case, the ultrasonic welding device is configured such that the first component and the opposing second component are displaceable relative to each other in a first displacement direction such that the reaction force acting on the components during the displacement opposite to the first displacement direction reaches but preferably does not exceed a predefined maximum force. In other words, the two components can be displaced until they are in direct or indirect stop contact with each other. It is possible to detect when the stop is reached and the inferred position of the components during this process. This can be achieved, for example, in that the drive that can be used to displace one or both of the components is capable of exerting at least a predefined maximum force, and preferably up to a predefined maximum force. Alternatively, a sensor system can be provided that can be used to measure the reaction force and that limits or stops the drive when the predefined maximum force is exceeded. The position at which the stop is assumed to have been reached can be read out, for example, from a control system that controls the drive of the components or can be recorded by a position sensor.

[0021] At least one or some of the components, in addition to being displaceable in a first displacement direction, are also displaceable in a second displacement direction extending transversely, preferably perpendicularly, to the first displacement direction. In other words, such components are not only displaceable with the face defining the receiving chamber facing the opposing component, i.e. perpendicular to this face, but also laterally, in particular perpendicularly thereto. In this case, the second displacement direction may preferably extend parallel to the face of the component in question that defines the receiving chamber.

[0022] It is possible to use the component displacement capabilities already described and the ability to detect direct or indirect stop contact between components moving relative to one another to obtain desired information about the current state of one or more components of an ultrasonic welding apparatus.

[0023] For this purpose, the first and second components are moved towards each other in a first displacement direction. For example, the anvil as the first component can be moved towards the sonotrode as the second component. The anvil can be arranged, for example, above the sonotrode so that the first displacement direction extends vertically downwards. The displacement movement in this case can start from an initial position in which the first and second components are initially located. The two components are moved towards each other in a first displacement direction until they are in direct or indirect contact with each other such that a reaction force is accumulated in the direction opposite to the displacement. As soon as this reaction force reaches a predetermined maximum force, the two components are assumed to be in rest contact with each other. Of this, a position or a relative position assumed by one of the two components or by both components is detected and registered as a first rest position.

[0024] After registering the first stop position, a second stop position is determined. For this purpose, the two components can first be moved slightly away from each other in a first displacement direction in order to release the pre-assumed stop contact. The two components can then be displaced relative to each other in a second displacement direction until a change position is assumed. In other words, the two components can be offset relative to each other laterally, i.e. preferably parallel to their facing faces. Starting from the change position or relative positioning, the two components are again moved towards each other in the first displacement direction in a further displacement operation until the reaction force reaches a predefined maximum force and, as a result, a stop contact is detected. The position assumed by one of the components, or the relative position of both components, is detected and registered as a second stop position.

[0025] Based on the first and second stop positions thus registered, conclusions can be drawn about the status information to be determined. For example, as described in more detail below, it is possible to detect where the first stop position is located relative to the second stop position and from this relative positioning, conclusions can be drawn about the status of the components inside the ultrasonic welding device. Alternatively, as also described in more detail below, multiple status information can be determined over time and compared with each other in order to draw conclusions about wear that occurs over time due to any changes.

[0026] For example, it can be detected whether the second stop position differs significantly from the first stop position with respect to the first displacement direction, which can be detected as an indication for the presence of a height difference. The height difference can result for example from a step or recess arranged on one of the faces of the first component and / or the second component that come into contact. Such a step or recess can be the result of wear effects, and depending on the height of the step or the depth of the recess it can be possible to draw a conclusion about any local wear present. In this way, it can already be possible to draw a conclusion about the presence of excessive wear on the basis of a single determination of the status information.

[0027] Alternatively, or in addition, it is possible to observe how the two stop positions change over time and draw conclusions from this about the current state of the components. For example, it can be detected that one or more stop positions shift over time and / or their relative positions with respect to each other change over time. This can be interpreted as an indication that the surfaces of the two components that are in contact change over time, for example due to wear. In this case, the change in the stop positions over time can provide a gauge for wear that has already occurred. For example, the currently determined state information can be compared with a previously known initial state, in particular a new state, or with a limit state that is assumed to have been exceeded by excessive wear.

[0028] According to one embodiment of the method according to the first aspect of the invention, method steps (b) and (c) are repeated a number of times to detect a number of second stop positions for different positions of the first component relative to the second component. In method step (d), status information is then determined based on the detected first stop position and the number of second stop positions.

[0029] In other words, the first and second components are preferably displaced several times in the second displacement direction to a changed position, and then a stop position is determined in each case by moving both components in the first displacement direction until they reach a stop. In this manner, it is possible to determine stop positions at several points along the surface where the first and second components meet with their sides facing each other. Overall, this makes it possible to record a certain height profile or surface profile along such surface. Such height profile or surface profile contains information that makes it possible to draw conclusions about the wear of the surface concerned, or more generally about the shape of such surface. As a result, it is possible to draw qualitative or quantitative conclusions about the current state of the component concerned.

[0030] According to one embodiment, in method steps (a) and (c), the first component and the second component are displaced relative to each other until a surface of the first component facing the second component contacts the second component.

[0031] In other words, to determine a stop position, the two components can be moved towards each other until direct contact is reached. The resulting direct contact between the opposing faces of both components then means that a significant reaction force counteracts further displacement along the first displacement direction, so that as soon as this reaction force reaches a predetermined maximum force, a corresponding stop position can be detected.

[0032] Alternatively, according to one embodiment, a matrix element may be introduced into the receiving chamber before carrying out method step (a) and / or method step (c), in which the first component and the second component may then be displaced relative to one another until the matrix element is in contact with the first component with a surface facing towards the first component and in contact with the second component with a surface facing towards the second component.

[0033] The matrix element is an object that fits into the receiving chamber and fills a partial volume of the receiving chamber. The matrix element may also be referred to as a template. The matrix element may be temporarily introduced into the receiving chamber for carrying out the method described herein, for example by an operator or a machine pushing the matrix element into the receiving chamber from one of the open sides. In this case, the matrix element is preferably dimensionally stable enough to not deform or not significantly deform under forces acting on the matrix element, at least up to a predefined maximum force. For example, the matrix element may be a solid or hollow body, made of a material that is able to withstand mechanical stresses, such as a metal. Thus, the first and second components may clamp the matrix element between them when they move towards each other. That is to say, the first and second components may be in indirect rest contact with each other via the matrix element. The reaction force acting here is then transmitted to the respective other components via the matrix element. As soon as the reaction force reaches the predefined maximum force, the respective rest position is detected. In this case, the rest position refers to the position of the two components with respect to the matrix element arranged between them. Since the dimensions of the matrix elements can be very accurately measured or are known in advance, the stopping positions can be accurately determined for both components.

[0034] According to a detailed embodiment, the matrix element may be attached to either the first component or the second component.

[0035] In other words, the matrix element may be temporarily attached to one of the components that are displaced towards each other while the method described herein is being performed, so that the matrix element is positioned with this component or displaced with this component. For example, the matrix element may be attached to the sonotrode so that it protrudes from the surface of the sonotrode that faces the anvil towards the anvil. As a result, the matrix element is fixed in a position corresponding to the sonotrode, while the anvil can be moved in a second displacement direction relative to the sonotrode and thus relative to the matrix element. In particular, the matrix element may be configured to be releasably and / or tool-free attached to the components.

[0036] According to further detailed embodiments, the matrix element has a smaller width on the side facing the first component or the second component compared to the surface of the first component or the second component contacted by the matrix element.

[0037] In other words, the matrix element has a narrower width on the side facing one of the components in terms of which stop position should be determined than the surface of the corresponding component with which it is contacted. For example, taking advantage of the fact that the surface of the sonotrode facing the receiving chamber is scanned, the matrix element can be narrower on the side facing the sonotrode than the surface of the sonotrode that is scanned. In this way, when the first and second components are moved towards each other, the matrix element can be in contact with the opposing component over a substantially smaller surface area than if the components were in direct contact with each other. Thus, the narrow side of the matrix element can "scan" the surface of the first or second component over a small area, similar to a sensor or probe.

[0038] According to further detailed embodiments, the matrix elements may have a greater width on the side facing the first component or on the side facing the second component than on the opposite side.

[0039] In other words, the matrix element may have one wide side and one narrow side. For example, the narrow side may have a width less than 50%, preferably less than 20%, or even less than 10% of the width of the wide side. In other words, the narrow side of the matrix element may for example be less than half the width of the surface on which it is placed, preferably less than 20% of the width, or even less than 10% of the width. For example, the narrow side may be configured as a narrow protrusion, as a narrow ledge, or as a point on the matrix element. For example, with respect to the wide side, the matrix element may be placed on and attached to the first or second component, facing the component. The narrow side may be directed towards the surface of the corresponding other component and may contact this surface over a small area to detect the stop position. Thus, for example, by means of the narrow side, the matrix element may also penetrate into a small or narrow local recess, so that the stop position may be detected relative to such a recess.

[0040] Previously, the displaceability of the various components inside the ultrasonic welding device was described in very general terms. In principle, it must be possible to displace at least one of two opposing components in a corresponding first displacement direction towards the opposing component. That is, it must be possible to displace a component such as an anvil, which is arranged above an opposing component such as a sonotrode, vertically downwards in a first displacement direction, and / or it must be possible to displace the other component vertically upwards. It must be possible to displace a component such as a lateral slide, which is arranged laterally adjacent to an opposing component such as a contact element, horizontally in a first displacement direction towards the other component. Furthermore, at least one of the components, or preferably two or more components, may have an additional degree of freedom of movement to the effect that the component may also be displaced in a second displacement direction. In this case, the components may be displaced, for example, by servo motors and controlled by a control system.

[0041] However, in a particular design of an ultrasonic welding apparatus, this general displaceability may be limited, i.e., all of the components may not be displaceable independently of all the other components, but instead, individual ones of the components may cooperate with one another and be displaced together at least in their respective displacement directions.

[0042] According to one embodiment, for example, the anvil may be displaceable laterally relative to the sonotrode in a first direction and relative to the sonotrode in a second direction, the contact element may be fixed to the anvil in the first direction and displaceable relative to the anvil in the second direction, and the lateral slide may be held stationary relative to the sonotrode in the first direction and displaceable relative to the sonotrode in the second direction.

[0043] In other words, the various components inside the ultrasonic welding device may each be displaced in a different way by one or more actuators, such as servo motors, and their movements may be guided in a different way. In the described embodiment, the anvil may be displaced in both a first direction and a second direction. In particular, the anvil may be displaced independently of the position of the sonotrode and independently of the position of the lateral slide. However, the contact element is fixed to the anvil in the first direction and thus cooperates with the anvil so that it can only move with the anvil in the first direction. However, in the second direction, the contact element may be displaced relative to the anvil. The lateral slide may then be held relative to the sonotrode so as to remain stationary relative to the sonotrode. In the case where the sonotrode itself is fixed in a stationary state, the lateral slide may thus also remain stationary in the first direction. However, the lateral slide may be displaced in a second direction relative to the sonotrode, transversely thereto.

[0044] The described configuration of components and freedom of movement can be implemented in an ultrasonic welding apparatus in an advantageous manner, for example in that the anvil is arranged above the sonotrode and can be moved in a first direction and a second direction by two actuators. In this case, the first direction corresponds to the vertical direction and the second direction corresponds to the horizontal direction. The contact element is attached to the anvil and is moved together with the anvil in the first direction. However, it can also be displaced in a second direction, i.e. horizontally, independently of the movement of the anvil by its own actuator. The sonotrode can be held stationary in the ultrasonic welding apparatus, and therefore does not need to have a displacement actuator. The lateral slide can be displaced relative to the sonotrode in the second direction and can have an actuator for this purpose.

[0045] In such a configuration of the ultrasonic welding apparatus, according to a detailed embodiment, in method step (a) the anvil can be displaced in a first direction starting from an initial position towards the sonotrode, in method step (b) the anvil can be displaced in a second direction to a changed position, and in method step (c) the anvil can be displaced in the first direction starting from the changed position towards the sonotrode.

[0046] Overall, the anvil can be moved to different lateral positions, i.e. positions at different positioning points along the second direction. In each case it can be displaced until it is in rest contact with the sonotrode. In this manner, the overlap area between the sonotrode and the anvil can be scanned progressively. The rest positions recorded in this process can reproduce the height profile of the sonotrode and / or the anvil in this overlap area. This height profile can contain information about the surface geometry at the sonotrode and / or the anvil. This makes it possible to determine information about the state of these components.

[0047] Alternatively, according to a detailed embodiment, the matrix element may be introduced into the receiving chamber before carrying out method step (a) and / or method step (c), where in method step (a) the lateral slide may be displaced in a second direction starting from an initial position towards the contact element, in method step (b) the contact element may be displaced in a first direction up to a modified position and in method step (c) the lateral slide may be displaced in the first direction towards the contact element in the modified position.

[0048] Overall, the lateral slide can be moved to different height positions relative to the contact elements, i.e. positions at different positioning points along the first direction. In each case, the lateral slide can be displaced in the second direction until it is in indirect rest contact with the contact elements. That is, the lateral slide can be displaced to a certain point towards the contact elements until it abuts against a matrix element located therebetween. In this manner, the overlapping area between the lateral slide and the contact elements can be scanned incrementally.

[0049] In this case, the matrix elements may advantageously be configured, i.e. for example provided with protrusions directed towards the contact elements, so that some unevenness of the contact elements can be detected over small areas. The stop positions recorded in this process may reproduce the surface profile of the contact elements and / or of the lateral slide in the overlapping areas. This surface profile may contain information about the surface geometry at the contact elements or at the lateral slide. This makes it possible to determine information about the state of these components.

[0050] According to one embodiment, the state information determined by the method is tested for a typical characteristic indicative of a previously known state of at least one of the components. - Start maintaining the ultrasonic welding equipment; - initiating replacement of at least one of the components of the ultrasonic welding device; - calculating the remaining useful life of at least one component of the ultrasonic welding device, optionally taking into account the detected typical characteristics; -emitting a signal indicating the presence of a previously known condition; - verifying the correct use of components used in ultrasonic welding equipment; - taking a camera image of at least one component of the ultrasonic welding device is initiated.

[0051] In other words, the already determined status information from at least two detected stop positions can be analyzed to determine whether the stop positions have a typical value, which is characteristic of a predefined status of one of the components. In this case, the value can be an absolute value or a relative value between the respective stop positions. For example, it can be analyzed whether the absolute value of the stop positions exceeds or falls short of a predefined limit value. In particular, the absolute value can be compared, for example, with a predefined reference value. For example, the behavior of the absolute value can characterize a certain wear indication at the component and / or a certain geometrical property of the component. Alternatively, the differences between the stop positions, in particular between adjacent stop positions, can be analyzed. Such differences can characterize a certain status of the component to be determined, in particular a certain wear indication and / or a certain geometrical property of the component.

[0052] Based on such analysis, for example, if it is identified that excessive wear on the component is highly likely, one or more actions may be initiated or suitable measurements may be made to proceed.

[0053] For example, a technician may be configured to maintain the ultrasonic welding device, where the technician may review the status information determined by on-site inspection of the ultrasonic welding device during the course of the presented method, and if, for example, excessive wear is detected or a predetermined wear limit is identified as having been reached, then corrective maintenance may be performed, e.g., during which the worn components may be put back into service.

[0054] Alternatively, one or more of the components may also be replaced in response to determined state information.

[0055] Furthermore, knowledge of typical characteristics of the condition information can also be used to determine the remaining useful life of one or more components of the ultrasonic welding device. In this case, the detected typical characteristics can be taken into account as necessary. For example, based on the determined condition information, conclusions can be drawn about wear that has already occurred at the component. If this wear can be quantitatively obtained from the condition information, it is possible to draw conclusions about possible further wear in the future and thereby analyze how long the affected component can still be expected to remain in a working condition before it has to be replaced or repaired. Such information can, for example, be used in the context of foreseeable maintenance, making it possible to plan maintenance work in advance.

[0056] Furthermore, a corresponding signal may be emitted if a previously known characteristic condition is detected by analyzing the condition information. For example, the signal may provide information to an operator or technician of the ultrasonic welding device to alert the operator or technician of the detected condition. For example, the signal may be emitted in a visual and / or acoustic manner to inform the operator or technician that the ultrasonic welding device must be maintained or that such maintenance is imminent. Alternatively, or in addition, the signal may be transmitted to another machine or to a monitoring center.

[0057] As a further possible response to the detection of the typical characteristics, it is possible to detect the exact use of the component used in the ultrasonic welding device. For example, different components are used in the ultrasonic welding device for different application purposes. For example, for a specific welding application, it is possible to use a specific sonotrode and / or anvil with an application-specific shape, for example the shape of a so-called Dombie nose. This shape can be detected when determining the stop position and the resulting height or surface profile. As a result, it can be automatically determined whether a component with the desired profile has actually been installed in the ultrasonic welding device.

[0058] Furthermore, the detection of the typical characteristic may trigger the activation of a camera to capture an image of at least one of the components of the ultrasonic welding device. The camera may be integrated in the ultrasonic welding device and may be preferably configured to be able to capture images of the faces of the components that may be subject to wear, for example. The images captured by the camera may be used for visual inspection of the components. For example, a supplementary analysis of the images may verify the condition of the components identified as possible within the scope of the methods presented herein, in particular the wear of the components. If necessary, the images may be documented or archived and / or analyzed in a supplementary manner.

[0059] According to a further embodiment, the status information can be determined multiple times in successive periods during operation of the ultrasonic welding device as an alternative or in addition to the inspection for the presence of the above-mentioned typical characteristics. Parts of the determined status information are compared for typical changes that refer to a previously known state of at least one of the components. Upon detection of a typical change, an action is initiated that can be selected from the group of possibilities already described for the preceding embodiment.

[0060] In other words, the status information can be determined several times in succession by detecting at least two stop positions, in each case at different times. In view of the detected stop positions, if the surface and / or the position of the component changes over time, the stop positions also change accordingly. By comparing the currently recorded stop positions with the already recorded stop positions, it is possible to draw conclusions about such changes. For example, from this it is possible to obtain information about any wear that has occurred in the interim.

[0061] An embodiment of an ultrasonic welding device according to the second aspect of the present invention is configured to carry out or control the method described herein. For this purpose, the ultrasonic welding device may comprise a control system for controlling actuators that can be used to displace components of the ultrasonic welding device in a first and / or second displacement direction in a targeted and controlled manner. The actuators can be composed of various means, such as precisely displaceable actuators, servo motors, pneumatic drives, hydraulic drives, etc. The control system may comprise microelectronic circuits that can be used to generate and transmit control signals to the actuators. In particular, the control system may be programmable. For this purpose, the control system may comprise a processor and a data storage device. The controller may further comprise and communicate with sensors.

[0062] The control system may be programmed using a computer program product to carry out or control the methods described herein in an ultrasonic welding apparatus according to the third aspect of the invention. The computer program product may be programmed in any computer language.

[0063] The computer program product may be stored on a machine-readable medium according to the fourth aspect of the invention. Such a machine-readable medium may be, for example, a portable electronic medium. It may preferably store data in a non-volatile memory. For example, the medium may be a flash memory, a CD, a DVD, a ROM, an EPROM, etc. Alternatively, the medium may be part of a computer or a server. In particular, the medium may be part of a cloud. Thus, the computer program product may be read or downloaded from the machine-readable medium, for example over a network such as the Internet.

[0064] Possible features and advantages of embodiments of the present invention are described herein partly with reference to an ultrasonic welding apparatus and partly with reference to a method of operation for the ultrasonic welding apparatus. Those skilled in the art will understand that the features described for individual embodiments can be transferred to other embodiments in a similarly suitable manner and can be adapted and / or exchanged to arrive at further embodiments of the present invention and possibly synergistic effects.

[0065] Advantageous embodiments of the present invention are further described below with reference to the accompanying drawings, in which neither the drawings nor the description should be construed as limiting the invention in any manner. [Brief description of the drawings]

[0066] [Figure 1(a)] 1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 1(b)] 1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 1(c)] 1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 1(d)] 1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 1(e)] 1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 1(f)]1A-1D show diagrams of components of an ultrasonic welding apparatus in various configurations during successive steps of a method according to an embodiment of the invention for recording a height profile at the sonotrode and / or anvil. [Figure 2(a)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a height profile at an anvil. [Figure 2(b)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a height profile at an anvil. [Figure 2(c)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a height profile at an anvil. [Diagram 3] 4 shows a height profile recorded by a method according to an embodiment of the present invention. [Figure 4(a)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a surface profile on a contact element. [Figure 4(b)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a surface profile on a contact element. [Figure 4(c)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a surface profile on a contact element. [Figure 4(d)] 1A-1D show diagrams of components of an ultrasonic welding apparatus including matrix elements inserted in a receiving chamber in various configurations during successive steps of a method according to one embodiment of the present invention for recording a surface profile on a contact element. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] The figures are only schematic and are not to scale. The same reference numbers in the various drawings indicate the same features or features with the same effect.

[0068] FIG. 1 shows an ultrasonic welding apparatus 1 at various stages during the performance of a method for determining status information according to one embodiment of the present invention.

[0069] The ultrasonic welding device 1 comprises a number of components 2 which are displaceable relative to one another. In particular, the ultrasonic welding device 1 comprises a sonotrode 3, an anvil 5, a contact element 7 and a lateral slide 9. These components 2 surround a receiving chamber 11 in which joining partners (not shown) can be accommodated for subsequent welding of the joining partners together. In this case, the receiving chamber 11 is defined on a first side from below by a face 13 of the sonotrode 3 and on a second side opposite the first side from above by a face 15 of the anvil 5. The receiving chamber 11 is defined on a third side from the right by a face 17 of the contact element 7 and further defined on the left by a fourth side opposite the third side by a face 19 of the lateral slide 9.

[0070] At least some of the components 2 are displaceable relative to other ones of the components 2. For this purpose, the relevant components 2 can be driven, for example, by adjusting drives controlled by a control system (not shown in each case).

[0071] In the example shown, the anvil 5 can be displaced perpendicularly to the sonotrode 3 in a first displacement direction 21. In the configuration shown in FIG. 1, the perpendicular first displacement direction 21 is also referred to as the first direction 29. Furthermore, the anvil 5 can be displaced in a second displacement direction 23 relative to the sonotrode 3. The horizontal second displacement direction 23 is also referred to as the second direction 31 in the configuration shown. The contact element 7 is fixed to the anvil 5 in the first direction 29, but can be displaced in the second direction 31 relative to the anvil 5. The transverse slide 9 is held stationary relative to the sonotrode 3 in the first direction 29, but can be displaced in the second direction 31 relative to the sonotrode 3. In this case, the transverse slide 9 can be moved in the horizontal first displacement direction 25 relative to the contact element 7 opposite it. Furthermore, by displacing the contact element 7 together with the anvil 5 in the vertical direction 29 , the lateral slide 9 and the contact element 7 can be moved relative to each other in a second displacement direction 27 .

[0072] Here, the mutually opposing components 2 can be displaced with respect to each other such that a reaction force acting between these components 2 can reach a maximum force, which is generated when the components 2 directly or indirectly come into rest contact with each other. When such a maximum force is reached, it can be concluded that the associated components 2 are in contact with each other as a result. The position assumed by one or both of the components 2 in this process can be detected as a rest position.

[0073] 1(a)-1(f) a sequence of method steps will now be described by which status information can be determined, providing information about the current state of at least one of the components 2. In the shown example, information about the geometry of the face 13 of the sonotrode 3 facing the anvil 5 and / or the face 15 of the anvil 5 facing the sonotrode 3 has to be determined as status information. In this case, the anvil 5 is referred to as the first component 33, while the opposing sonotrode 3 is referred to as the second component 35.

[0074] As shown in FIG. 1(a), in the initial configuration, the component 2 is arranged such that the anvil 5 having surface 15 is at a fixed distance from the sonotrode 3 having surface 13, and the contact element 7 having surface 17 is at a fixed distance from the lateral slide 9 having surface 19, so that the receiving chamber 11 is relatively large.

[0075] Starting from this configuration, as shown in Fig. 1(b), the anvil 5, together with the contact element 7 held thereon, is displaced vertically towards the sonotrode 3 in a first displacement direction 21 until both components 2 are in rest contact with each other, i.e. in this case both components 2 are in direct contact, so that a reaction force counteracts the further displacement of the anvil 5. As soon as this reaction force reaches a predetermined maximum force, the position assumed in the process by the anvil 5 is recorded as the first rest position.

[0076] 1(c), the anvil 5 is then detached again from the sonotrode 3. The anvil 5 is then displaced in a horizontal second displacement direction 23 relative to the sonotrode 3 into a change position. For this purpose, the lateral slide 9 can be moved in the second displacement direction 23 towards the contact element 7.

[0077] Starting from this changed position, the anvil 5 is then displaced once more in a displacement direction 21 perpendicularly towards the sonotrode 3, as shown in FIG. 1(d). As soon as both components 2 are in stop contact and the reaction force reaches a predefined maximum force, the second stop position is detected.

[0078] The method steps shown in Figures 1(c) and 1(d) can be repeated multiple times and, if necessary, in this process the anvil 5 can be displaced stepwise further in the horizontal second displacement direction 23 and stopped at a position determined in each case.

[0079] 1(e) and 1(f) show a configuration in which the anvil 5 has been pre-displaced in the horizontal second displacement direction 23 to a certain point, such that the face 15 of the anvil 5 and the face 13 of the sonotrode 3 only slightly overlap laterally. In this configuration, the receiving chamber 11 consequently has only a narrow width. Its width can approximately correspond to the width typically occupied during welding of the joining partners. During welding, wear can occur in the component 2 due to the pressure and friction caused by the process. As shown in figs. 1(a) to 1(f), for example, due to such wear, a recess 36 or a notch can appear on the face 13 of the sonotrode and / or a recess 37 or a notch can appear on the face 15 of the anvil 5. Since in the configuration shown the anvil 5 and the sonotrode 3 overlap only in one area where at least one of these recesses 36, 37 is located, the contact between the anvil 5 and the sonotrode 3 occurs at a slightly different stop position than in the previous configuration (shown in Figures 1(a) to 1(d)). As a result, such differences in the measured stop positions can provide information about one or two recesses 36, 37 created by wear.

[0080] 2(a)-2(c) show an alternative embodiment of the method described herein, in which a matrix element 39 is inserted into the receiving chamber 11 between the components 2 of the ultrasonic welding device 1. In the shown example, the matrix element 39 may be attached, for example, to the sonotrode 3. For example, the matrix element 39 may be arranged at the edge of the sonotrode 3 that is furthest away from the lateral slide 9. In this case, the matrix element 39 may be arranged at the face 13 of the sonotrode in the region of the recess 36 caused by wear. Here, the matrix element 39 may protrude upwards above the face 13 of the sonotrode 3 towards the anvil 5. The matrix element 39 preferably has a small width in order to enable it to locally contact or scan the facing face 15 of the anvil 5 in a narrow area. In particular, the width of the matrix element 39 may be smaller than the width of the face 15 of the anvil 5 with which it is contacted.

[0081] In the alternative embodiment shown in FIG. 2, the anvil 5 and the sonotrode 3 are moved vertically towards each other several times, similar to the embodiment shown in FIG. 1, and in each case displaced horizontally relative to each other to different positions between them. In this case, however, the anvil 5 with its face 15 does not come into direct contact with the face 13 of the sonotrode 3. Instead, when both components 2 approach each other, a matrix element 39 is clamped between the components 2 and its upper and lower ends come into contact with the mutually facing faces 13, 15 of the sonotrode 3 and the anvil 5. The clamping of the matrix element 39 results in an increase in the reaction forces caused when the two components 2 approach each other, and when a certain maximum force is exceeded, the stop position can be determined accurately even in this case. As can be seen in particular in FIG. 2(c), in this case, due to the narrow width of the matrix element 39, it is possible to detect even narrow recesses 36, 37 on the faces 13, 15 that come into contact.

[0082] FIG. 3 shows a height profile that can be recorded using the method described herein, where stop positions a, b, c have been determined at various positions along the horizontal displacement direction 23 at corresponding heights h. In this case, the various positions correspond to the configurations shown in FIG. 1(b), FIG. 1(d), FIG. 1(f) or FIG. 2(a), FIG. 2(b), FIG. 2(c), respectively. It can be seen that the last recorded data point c shows a lower height than the preceding data points a, b. From this, it can be seen that when data point c is recorded, the anvil 5 and the sonotrode 3 can be moved further towards each other than when the other data points were recorded. This can be identified as a typical characteristic of a condition that is often found in one of the components 2, e.g. the anvil 5, in the form of a localized depression 37 in the area around position (c). Such a condition is known beforehand and is a typical wear symptom that can occur in the ultrasonic welding device 1.

[0083] If more than the three data points shown in the examples are recorded, the data points may also represent a sufficiently high resolution height profile that it is possible to obtain information about the position, width, depth and / or geometric shape of one or two recesses 36, 37 as status information.

[0084] Alternatively, or in addition, the status information may be recorded at successive points in time. For example, the method described herein may be performed periodically at predefined intervals or according to a predefined operation duration and stop position stored as status information. Alternatively, the method may be performed periodically after a predefined number of welding operations have been completed or after it has been determined that a predefined amount of energy has been consumed by the welding operations performed in the interim, and the stop position may be stored as status information. The currently recorded status information may be compared in the process with predefined status information. In this case, it is possible to draw conclusions about the monitored status of the component 2 inside the ultrasonic welding device 1 from the observed changes.

[0085] Depending on the need, the method described herein can be carried out once without the matrix element 39, i.e. as shown in FIG. 1, and once with the matrix element 39, i.e. as shown in FIG. 2. When the method is carried out without any matrix element 39 accommodated in the receiving chamber 11, in this case the anvil 5 and the sonotrode 3 overlap only in the area of ​​the respective recesses 36, 37 (see FIG. 1(f)), height information is generated upon reaching a stop position influenced by the sum of the two recesses 36, 37 both on the sonotrode 3 and on the anvil 5. In contrast, when the method is carried out with the matrix element 39 accommodated in the receiving chamber 11, in the case where the anvil 5 and the sonotrode 3 overlap only in the area of ​​the respective recesses 36, 37, height information is generated upon reaching a stop position influenced in the shown example only by the recess 37 on the anvil 5. By subtracting both height information from each other, it is finally possible to generate height information reflecting the recess 36 on the sonotrode 3. Instead of fixing the matrix element 39 to the sonotrode 3, the matrix element 39 can alternatively also be fixed to the anvil, as shown in figure 2. As a result, in this case the recesses 36 on the sonotrode 3 can be detected.

[0086] Upon detecting a typical characteristic in the condition information or a typical change between condition information recorded successively in time, this can be used as an indication for a change in one or more of the components 2 and a suitable response can be initiated. For example, a reference value or a reference height profile can be used for the comparison. In this case, it may be possible to demonstrate a wear limit. If the wear limit is exceeded, maintenance can be constituted. Preventive maintenance can also be scheduled, for example, if excessive wear is predicted in the near future based on the currently determined condition information. For example, after performing a certain number of welding operations, the condition information can be determined according to the invention and then an estimation can be made as to the period for which the component 2 will still be used. Intermediate steps can also be performed to make a kind of prediction. Defective components 2 can be identified in time.

[0087] Overall, excessive periods of tool use can be prevented. Wear limits can be identified in time. Maintenance and tool changes can be better planned. Human influence can be minimized. With an adjusted workflow and maintenance plan, tools can be replaced or reworked in time. Any noteworthy issues can be relevant for follow-up. For example, upon detection of excessive wear on the component 2 of the ultrasonic welding device 1, it is also possible to check whether the last joining partner joined with the ultrasonic welding device 1 was properly welded. If the determined status information deviates significantly from the target value, the ultrasonic welding device can be taken out of service completely if necessary and / or a suitable signal can be emitted to provide the operator and / or the monitoring system with information about the detected deviation. For example, an acoustic alert can be emitted and / or a warning light can be activated, for example on a traffic light warning system.

[0088] Possibly supplementing the determination of condition information as described herein, a detected change in condition, such as local wear detected on one of the components 2, can be further verified via an integrated or external camera system. For example, if a limit is not reached, an image of, for example, the profile of the face 15 of the anvil 5 can be generated. Such further visual inspection can also be used to document or even evaluate further wear patterns.

[0089] Alternatively, or in addition, the status information may be used to detect, for example, whether the correct component 2, i.e., anvil 5 having the desired geometric shape (i.e., for example, a Dombie nose), has been installed in the ultrasonic welding apparatus 1. Even if a component 2 has been replaced in the ultrasonic welding apparatus 1, it is possible to detect whether the correct component 2 has been replaced and / or whether it has been properly mated.

[0090] Figures 4(a) to 4(d) show the successive steps of a method according to an alternative embodiment, where the method is adapted to determine status information on the basis that in particular wear on the contact element 7 can be detected. In this case, the lateral slide 9 is referred to as the first component 33, whereas the opposing contact element 7 is referred to as the second component 35.

[0091] In the described embodiment, the matrix element 39 is inserted into the receiving chamber 11 in a manner similar to that of the previously described embodiments. The matrix element 39 has, at its side facing the lateral slide 9, a width B1 that is greater than the width B2 of its opposite side facing the contact element 7. In this case, the term "width" is to be understood as the dimension perpendicular to the first displacement direction 21. The "first displacement direction" 21 is generally defined here as the direction of movement of the first component 33 and the second component 35 that are moved relative to each other, i.e. in this case the direction of movement of the lateral slide 9 or the contact element 7. As a result, in this case the first displacement direction is oriented horizontally.

[0092] In the particular embodiment shown, the matrix element 39 is arranged in such a way that it is placed over a relatively large area on the face 19 of the lateral slide 9 facing the receiving chamber 11 and is preferably attached to the lateral slide 9. There is a protrusion 41 arranged on the opposite side, which side is directed towards the face 17 of the contact element 7 facing the receiving chamber 11. The protrusion 41 has a narrower width B2 or is tapered or pointed. Thus, the matrix element 39 with the protrusion 41 can also engage in small recesses 37 that may be present on the contact element 7.

[0093] FIG. 4(a) shows an initial configuration in which the components 2 are spaced far enough apart from each other so that the matrix elements 39 can be inserted into the receiving chamber 11 with sufficient lateral clearance.

[0094] From this configuration, as shown in Fig. 4(b), the lateral slide 9 integral with the matrix element 39 can be moved in a horizontal first displacement direction 21 towards the contact element 7 until the protrusion 41 of the matrix element 39 contacts the face 17 of the contact element 7, and the reaction force accumulates until it reaches a maximum force. Thus, the first stop position is detected.

[0095] This first stop contact is released again by moving the lateral slide 9 backwards, after which the contact element 7 together with the anvil 5 is moved vertically downwards, as shown in Fig. 4(c) . In other words, the lateral slide 9 together with the matrix element 39 and the contact element 7 are displaced in a second displacement direction 23 perpendicular to each other into a changed position.

[0096] Starting from this changed position, the lateral slide 9 integral with the matrix element 39 is then displaced again to the right in the horizontal first displacement direction 21, as shown in FIG. 4(d). As a result, with its protrusion 41, the matrix element 39 can be in rest contact with the face 17 of the contact element 7 in the region of the recess 37. In other words, due to the specific design of the matrix element 39 with the local protrusion 41, the face 17 of the contact element 7 can be finely scanned and any wear-caused recesses 37 or roughness can for example be detected. If the method steps are repeated several times, as shown in FIGS. 4(c) and 4(d), and the vertical displacement in the second displacement direction 23 occurs in small steps, a surface profile of the face 17 of the contact element 7 with a sufficiently high resolution can be recorded. This can be used to obtain detailed information about the current state of this contact element 7.

[0097] Finally, it should be noted that terms such as "comprise", "include" and the like do not exclude any other elements or steps, and "a" or "a" does not exclude a plurality. It should further be pointed out that features or steps described with reference to one of the above exemplary embodiments can also be used in combination with other features or steps of the above exemplary embodiments. Reference numbers in the claims should not be considered as limiting. [Explanation of symbols]

[0098] 1 Ultrasonic welding device 2. Components 3 Sonotrode Assembly 5. Anvil 7 Contact Elements 9 Horizontal Slide 11 Receptor Chamber 13 Sonotrode Surface 15 Anvil Face 17 Contact Element Faces 19 Side slide surface 21 First displacement direction of the anvil relative to the sonotrode 23 Second displacement direction of the anvil relative to the sonotrode 25 first displacement direction of the lateral slide relative to the contact element 27 second displacement direction of the lateral slide relative to the contact element 29 First Direction 31 The Second Direction 33 First Component 35 Second Component 36 Recess 37 Recess 39 Matrix Elements 41 Protrusion

Claims

1. A method for determining status information for an ultrasonic welding apparatus (1), comprising: the status information specifying in detail information about a current status of at least one component (2) of the ultrasonic welding apparatus (1); The ultrasonic welding apparatus (1) A plurality of components (2), sonotrode (3), and / or anvil (5), and / or contact element (7), and / or A plurality of components (2) each having a lateral slide (9); a receiving chamber (11) in which a joining partner is received, the receiving chamber (11) is bounded on a first side by a surface (13) of a first component (33) of the components (2), in particular the sonotrode (3), and on a second side opposite to the first side by a surface (15) of a second component (35) of the components (2), in particular the anvil (5), the receiving chamber (11) is optionally further defined on a third side by a face (17) of a third one of the components (2), in particular the contact element (7), and on a fourth side opposite to the third side by a face (19) of a fourth one of the components (2), in particular the lateral slide (9), at least the first component (33) of the components (2) and the second component (35) facing the first component (33) of the components (2) are displaceable relative to each other in a first displacement direction (21) toward each other and are displaceable relative to each other in a second displacement direction (23) oriented transversely to the first displacement direction (21), said first component (33) and said second component (35) are displaceable relative to one another in said first displacement direction (21) such that a reaction force acting on said first component (33) opposite said first displacement direction (21) reaches a predetermined maximum force, The method comprises the following method steps: (a) displacing the first component (33) and the second component (35) relative to one another starting from an initial position in the first displacement direction (21) and detecting a first stop position at which the reaction force acting on the first component (33) during the displacement reaches the predetermined maximum force, (b) displacing the first component (33) and the second component (35) relative to each other in the second displacement direction (23) to a changed position; (c) displacing the first component (33) and the second component (35) again relative to one another in the first displacement direction (21) starting from the changed position and detecting a second stop position in which the reaction force acting on the first component (33) during the displacement reaches the predetermined maximum force. (d) determining the status information based on the detected first stopping position and the detected second stopping position;

2. said method steps (b) and (c) being repeated a number of times to detect a number of second stop positions for different positions of said first component (33) relative to said second component (35); The method of claim 1 , wherein in method step (d) the status information is determined based on the detected first stop position and the plurality of second stop positions.

3. 3. The method according to claim 1, wherein in the method steps (a) and (c), the first component (33) and the second component (35) are displaced relative to each other until a face of the first component (33) facing the second component (35) contacts the second component (35).

4. Prior to carrying out method step (a) and / or method step (c), a matrix element (39) is introduced into the receiving chamber (11), 3. The method according to claim 1, wherein in the method steps (a) and (c), the first component (33) and the second component (35) are displaced relative to each other until the matrix element (39) has a face directed towards the first component (33) in contact with the first component (33) and a face directed towards the second component (35) in contact with the second component (35).

5. The method of claim 4, wherein the matrix element (39) is attached to either the first component (33) or the second component (35).

6. the width of the side of the matrix element (39) facing the first component (33) or the second component (35) is smaller than the face of the first component (33) or the second component (35) that is contacted by the matrix element (39); The method according to one of claims 4 and 5.

7. 7. The method according to claim 4, wherein the width of the side of the matrix element (39) facing the first component (33) or the side facing the second component (35) is greater than the width of the opposite side.

8. the anvil (5) is displaceable relative to the sonotrode (3) in a first direction (29) and transversely relative to the sonotrode (3) in a second direction (31); said contact element (7) being fixed to said anvil (5) in said first direction (29) and displaceable relative to said anvil (5) in said second direction (31); The method according to any one of claims 1 to 7, wherein the lateral slide (9) is held stationary relative to the sonotrode (3) in the first direction (29) and is displaceable relative to the sonotrode (3) in the second direction (31).

9. In method step (a), the anvil (5) is displaced in the first direction (29) starting from the initial position towards the sonotrode (3), In method step (b), said anvil (5) is displaced in said second direction (31) to said changed position, 9. The method according to claim 8, wherein in method step (c) the anvil (5) is displaced in the first direction (29) starting from the altered position towards the sonotrode (3).

10. Prior to carrying out method step (a) and / or method step (c), a matrix element (39) is introduced into the receiving chamber (11), In method step (a), said lateral slide (9) is displaced in said second direction (31) starting from said initial position towards said contact element (7), In method step (b), said contact element (7) is displaced in said first direction (29) to said changed position, 9. The method according to claim 8, wherein in method step (c) the lateral slide (9) is displaced in the second direction (31) towards the contact element (7) in the changed position.

11. the determined status information is tested for typical characteristics indicative of a previously known status of at least one of said components (2); Upon detection of typical characteristics, Starting maintenance of the ultrasonic welding apparatus (1); Initiating replacement of at least one of the components (2) of the ultrasonic welding device (1); - calculating the remaining useful life of at least one component (2) of said ultrasonic welding device (1), optionally taking into account said detected typical characteristics; generating a signal indicative of the presence of said pre-known condition; Verifying the correct use of the components (2) used in the ultrasonic welding device (1); taking a camera image of at least one component (2) of the ultrasonic welding device (1); The method according to any one of claims 1 to 10, wherein an action selected from the group comprising:

12. the condition information is determined a number of times during successive periods during operation of the ultrasonic welding device (1) and the determined condition information is compared for typical changes indicative of a previously known condition of at least one of the components (2); Typical changes detected: Starting maintenance of the ultrasonic welding apparatus (1); Initiating replacement of at least one of the components (2) of the ultrasonic welding device (1); - calculating the remaining useful life of at least one component (2) of said ultrasonic welding device (1), optionally taking into account said detected typical characteristics; Emitting a signal indicative of the existence of a previously known condition; Verifying the correct use of the components (2) used in the ultrasonic welding device (1); The method according to any one of claims 1 to 11, wherein an operation is initiated selected from the group comprising: taking a camera image of at least one component (2) of the ultrasonic welding device (1).

13. An ultrasonic welding device (1), comprising: A plurality of components (2), Sonotrode (3) and / or anvil (5) and / or contact element (7) and / or A plurality of components (2) each having a lateral slide (9); a receiving chamber (11) in which a joining partner is received, the receiving chamber (11) is bounded on a first side by a surface (13) of a first component (33) of the components (2), in particular the sonotrode (3), and on a second side opposite to the first side by a surface (15) of a second component (35) of the components (2), in particular the anvil (5), said receiving chamber (11) being defined on a third side by a face (17) of a third component of said component (2), in particular of said contact element (7), and further optionally defined on a fourth side opposite said third side by a fourth component of said component (2), in particular of a face (19) of said lateral slide (9); at least a first component (33) of said components (2) and a second component (35) of said components (2) facing said first component (33) are displaceable relative to each other in a first displacement direction (21) towards each other and in a second displacement direction (23) directed transversely to said first displacement direction (21), the first component (33) and the second component (35) are displaceable relative to one another in the first displacement direction (21) such that a reaction force acting on the first component (33) opposite to the first displacement direction (21) does not exceed a predetermined maximum force, An ultrasonic welding apparatus (1), wherein the ultrasonic welding apparatus (1) is configured to perform or control the method according to any one of claims 1 to 12.

14. A computer program product comprising instructions which, when executed on a processor, cause the processor to perform or control the method according to any one of claims 1 to 12 in an ultrasonic welding apparatus (1) according to claim 13.

15. 15. A machine-readable medium having the computer program product of claim 14 stored thereon.

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