C Frame Ultrasonic Welding Gun with Integrated Anvil
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Solution Overview
Problem
Current vehicle production welding systems face inefficiencies in heat production and tooling requirements, particularly in ultrasonic welding processes, where achieving precise heat application and minimizing additional tooling is challenging.
Innovation Solution
A weld gun system comprising a motor coupled to a converter and a horn, where the converter is also connected to a booster, allowing the horn to vibrate and produce heat for welding, with an integral anvil eliminating the need for separate tooling, and capable of fine-tuning energy amplitude for efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate tooling is used for ultrasonic welding, then welding function is achieved, but device complexity increases
Solution Approach 1:
The patent combines the anvil and tooling into a single integrated component. The anvil is designed with built-in tooling features that perform multiple functions including supporting the workpiece, providing the reaction surface for welding, and enabling precise positioning. This integration eliminates the need for separate tooling components while maintaining all necessary welding functions.
2Reliability
If traditional welding systems are used, then welding capability is provided, but heat production efficiency is reduced
Solution Approach 1:
The patent employs ultrasonic vibration at high frequency (typically 20-40 kHz) to generate heat through mechanical energy conversion. The horn delivers vibrational energy to the workpiece interface, creating friction and molecular agitation that produces localized heat precisely where needed. This mechanical vibration-based heating is significantly more efficient than traditional thermal methods as it converts electrical energy directly to mechanical vibration and then to heat with minimal losses.
3Manufacturing precision
If horn vibration is used to produce heat, then welding precision is improved, but energy amplitude control is challenging
Solution Approach 1:
The patent incorporates feedback mechanisms including sensors that monitor welding parameters such as force, temperature, and vibration amplitude in real-time. This feedback is fed to a control system that automatically adjusts the ultrasonic generator and pressurization system to maintain optimal welding conditions. The feedback loop ensures precise control of energy amplitude despite variations in material properties or environmental conditions.
Solution Approach 2:
The patent utilizes variable frequency and amplitude control of the ultrasonic horn to optimize welding for different materials and configurations. The system can dynamically adjust operating parameters including vibration amplitude, frequency, and duty cycle to match the specific requirements of each welding task. This parameter flexibility enables precise heat control while maintaining ease of operation across diverse welding applications.
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 system effectively produces heat for welding through horn vibration, reducing the need for additional tooling and enhancing welding precision and efficiency by integrating the anvil and fine-tuning energy amplitude, thus improving the vehicle production process.
Implementation Method 1
a converter (16) operably coupled between the motor (12) and the booster (14). The converter (16) may be configured to convert electrical energy into mechanical energy
Implementation Method 2
The horn (18) may be constructed and arranged to vibrate and the vibration of the horn (18) may produce heat in order to weld a piece (22)
Data Source
AI summary
A number of variations may include a weld gun and a method of operating the weld gun including a motor operably coupled to a converter. The converter may be operably coupled to a booster. A horn may be operably coupled to the booster. An anvil may be operably coupled to the horn wherein vibration of the horn may be caused by the motor. Moreover, the vibration of the horn may produce heat in order to weld a piece which may be disposed adjacent to the horn. The weld gun may not require separate or additional tooling.