Ultrasonic Welding Anvil Clamping for Compression Chamber Stability
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Solution Overview
Problem
Existing ultrasonic welding technologies face challenges in preventing the bending of the compression chamber, especially when welding stranded conductors with large cross sections, leading to poor weld quality.
Innovation Solution
An ultrasonic welding apparatus with a clamping device that applies a clamping force to the anvil's engaging surface, forming an obtuse angle with the sonotrode's working surface, effectively preventing compression chamber bending by ensuring symmetrical and robust force application, using a clamping mechanism that can be adjusted and includes a pulling device for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid compression chamber design is used to reduce lever forces and torques, then the structural stability is improved, but bending of the anvil part still occurs when welding larger cross sections, resulting in poor weld quality
Solution Approach 1:
The anvil is clamped in a predetermined welding position before the welding process begins. The clamping device applies clamping forces to secure the anvil against the side delimiters, preventing bending during compression of large cross-section conductors.
Solution Approach 2:
The clamping device enables dynamic adjustment of the anvil position and clamping forces. The clamping forces can be adapted based on the specific welding task, allowing optimization between structural stability and prevention of anvil bending for different conductor sizes.
2Force
If holding yoke clamping means are used to clamp the anvil against side delimiters, then air gaps are avoided and larger forces can be channeled into the compression chamber, but bending of the compression chamber cannot be effectively prevented when welding large cross sections
Solution Approach 1:
The clamping device applies clamping forces at specific locations on the anvil (at the front and/or at the rear) rather than uniformly across the entire anvil. This localized clamping approach prevents bending of the compression chamber by targeting critical areas where forces are most needed.
Solution Approach 2:
The clamping forces are applied in multiple directions and locations (front and rear of the anvil) rather than from a single point. This multi-dimensional approach to force application provides comprehensive stabilization of the compression chamber during welding of large cross-section conductors.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution prevents compression chamber bending, ensuring high-quality welds for stranded conductors with large cross sections by providing a robust and compact design that maintains consistent force application, suitable for various materials and welding configurations.
Implementation Method 1
the anvil can be clamped at least in a welding position by means of a clamping device by a clamping force in the direction of the sonotrode
Implementation Method 2
ultrasonic welding apparatus with a clamping device and a method for ultrasonic welding of a welding material
Data Source
AI summary
An ultrasonic welding apparatus (50) includes a sonotrode (8) with a working surface (10), an anvil (4) with a working surface (11), which lies opposite the working surface (10) of the sonotrode (8), and two side delimiters (5, 6) with respective side delimiting surfaces (12, 13). The working surfaces (10, 11) and the side delimiting surfaces (12, 13) delimit a compression chamber (9) for placing an elongated welding material (60) in a welding material direction (B). The ultrasonic welding apparatus (50) has a clamping device (14), by which the anvil (4) is clamped at least in a welding position (S) by a clamping force, which acts on at least part of a side (15) of the engaging surface (26) of the anvil (4) that lies opposite the working surface (11) of the anvil (4), in the direction of the sonotrode (8). A method for ultrasonic welding is also disclosed.