Ultrasonic Joining Anvil Temperature Control for Clearance Stability
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Solution Overview
Problem
Conventional ultrasonic joining apparatuses require frequent clearance adjustments between anvils and the ultrasonic horn due to varying wear and temperature conditions, leading to unstable joining quality and impractical manufacturing line suspensions.
Innovation Solution
An ultrasonic joining apparatus with a rotator made of a heat-expandable material, featuring multiple anvils with integrated temperature adjustment mechanisms and heat transmitters, allowing for per-anvil clearance adjustments to maintain consistent joining quality without frequent line suspensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple anvils are provided on the rotating drum, then ultrasonic joining can be performed on multiple positions simultaneously, but the peripheral length and radial length of the rotating drum change with temperature variations, causing different clearances between anvils and ultrasonic horn
Solution Approach 1:
The patent applies parameter changes by making the rotating drum and anvils temperature-dependent. The rotating drum is made of a material with high thermal expansion coefficient, and the anvils are heated to a predetermined temperature before use. This temperature parameter change causes the rotating drum and anvils to expand, compensating for wear and maintaining consistent clearances between the ultrasonic horn and anvils across all positions, thereby resolving the contradiction between high productivity and precise clearance control.
2Ease of operation
If a large tolerance for clearances is employed, then frequent adjustments are reduced, but joining quality becomes unstable due to varying wear conditions
Solution Approach 1:
The patent implements preliminary action by heating the anvils to a predetermined temperature before the ultrasonic joining process begins. This pre-heating causes the anvils to expand to a predetermined dimension, compensating for wear that occurs during operation. By performing this temperature adjustment in advance, the system maintains consistent clearance and joining quality throughout the manufacturing process without requiring frequent interruptions for adjustment.
Solution Approach 2:
The patent utilizes thermal expansion as the core mechanism to resolve the contradiction. The rotating drum and anvils are designed to expand when heated to a predetermined temperature. This thermal expansion compensates for the wear that occurs during prolonged operation, maintaining consistent clearances between the ultrasonic horn and anvils. This allows the system to maintain high joining quality stability without frequent adjustments, as the thermal expansion continuously compensates for wear-induced clearance changes.
3Strength
If the rotating drum is made of metal, then structural strength is maintained, but temperature changes cause peripheral length and radial length variations affecting anvil positioning
Solution Approach 1:
The patent applies thermal expansion by selecting a metal material for the rotating drum with high thermal expansion coefficient and heating it to a predetermined temperature. This controlled thermal expansion compensates for wear and maintains precise anvil positioning. The high-temperature heating causes the metal rotating drum to expand radially and peripherally, counteracting the dimensional changes that would otherwise occur due to wear, thereby maintaining manufacturing precision while retaining structural strength.
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 simplifies clearance adjustments and reduces tolerance, enhancing the stability and quality of ultrasonic joining by allowing temperature-controlled expansion of the rotator and anvils, thus maintaining consistent ultrasonic joining quality without frequent manufacturing line interruptions.
Implementation Method 1
a rotator (110) made of a member to be expanded or contracted by heat
Implementation Method 2
an ultrasonic horn (120) configured to output ultrasonic vibrations
Implementation Method 3
a heater configured to heat the rotator (110)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An anvil 200 has a temperature adjustment mechanism 262 including a heater. The anvil 200 has a heat transmitter 261 transmitting heat generated by the temperature adjustment mechanism 262. The anvil 200 has a temperature sensor 270 detecting a temperature of an anvil attachment portion 112a in which the anvil 200 of rotating drum 110 installed. The ultrasonic joining apparatus 100 includes a controller configured to control a temperature to which the rotating drum 110 should be heated by the temperature adjustment mechanism 262. The controller controls a heat generation amount of the temperature adjustment mechanism 262 on the basis of a detection result by the temperature sensor 270. The temperature adjustment mechanism 262 and the heat transmitter 261 are installed in each of the multiple anvils 200.