Lateral-Mounted Sonotrode Transformer for Compact Friction Welding
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Solution Overview
Problem
Conventional ultrasonic oscillating systems with sonotrodes face issues such as increased length due to converter placement on the end face, leading to additional vibration components and space constraints, which hinder efficient in-plane oscillation for friction welding.
Innovation Solution
The ultrasonic oscillating system features a converter connected to the outer surface of the sonotrode, specifically the core or wing element, minimizing energy loss and allowing for a compact design by reducing the overall length, with an asymmetrical arrangement enabling the converter to be placed alongside without extending the sonotrode, and utilizing a chamfered sealing surface and strategically positioned webs to enhance vibration homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the converter is arranged on the end face of the sonotrode, then the sonotrode can be excited with longitudinal vibration, but the overall length of the ultrasonic oscillating system increases
Solution Approach 1:
The converter is moved from the end face (longitudinal dimension) to the lateral surface (radial dimension) of the sonotrode. This dimensional relocation allows the converter to be positioned in a different spatial plane, enabling excitation without extending the longitudinal length of the sonotrode assembly.
Solution Approach 2:
The converter is positioned asymmetrically on the lateral surface of the sonotrode rather than symmetrically on the end face. This asymmetric arrangement on the lateral surface enables effective excitation while maintaining a compact longitudinal profile.
2Power
If the converter is arranged on the end face of the sonotrode, then the sonotrode can be excited, but additional vibration components perpendicular to the sealing surface occur
Solution Approach 1:
By relocating the converter from the end face to the lateral surface, the excitation is applied in a different orientation that produces primarily in-plane vibration of the sealing surface, minimizing perpendicular vibration components and improving vibration homogeneity.
3Ease of manufacture
If the sonotrode is enlarged in the longitudinal direction to accommodate the converter, then the converter can be installed, but user-specific installation space requirements cannot be met
Solution Approach 1:
The converter is installed on the lateral surface of the sonotrode rather than extending the longitudinal dimension. This allows the overall length to remain compact while providing adequate space for converter installation and operation, meeting various installation space requirements.
4Power
If the converter acts on the end face of the sonotrode, then excitation is achieved, but energy loss in vibration transmission increases
Solution Approach 1:
The converter positioned on the lateral surface creates a more direct vibration transmission path to the sealing surface, reducing energy loss compared to end-face excitation which requires transmission through the entire longitudinal structure.
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
This configuration achieves reduced deformation of the sealing surface, minimized energy loss, and increased movement of the sealing surface, ensuring effective in-plane vibration for efficient friction welding without lengthening the sonotrode, thus addressing space constraints and vibration efficiency.
Implementation Method 1
an ultrasonic oscillating system (1) with a sonotrode... wherein the wing element has a sealing surface (7) which is intended to come into contact with a material for its processing
Implementation Method 2
the converter or amplitude transformer is connected to the wing element or the core element... the energy loss when the vibration is transmitted from the converter or amplitude transformer to the sonotrode is minimized
Implementation Method 3
A converter (9) with corresponding piezo elements (10) is used for excitation, which convert an electrical alternating voltage into a longitudinal mechanical ultrasonic vibration
Implementation Method 4
the sealing surface is moved back and forth on the material to be processed and friction welding takes place
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an ultrasonic vibration system (1) comprising a sonotrode which has two sonotrode end faces (8, 8') and a circumferential lateral surface that connects said sonotrode end faces (8, 8') with each other. The sonotrode has an elongate core element (2) and at least one wing element (3, 4), each core element (2) and wing element (3, 4) longitudinally extending from the one sonotrode end face (8) to the other sonotrode end face (8'). The wing element (3, 4) has a sealing surface (7) which is designed to be in contact with a material for the purpose of processing same and which is connected to the core element (2) via a plurality of longitudinally interspaced connecting portions (5, 6). The ultrasonic vibration system further comprises a converter (9) which is optionally connected to the sonotrode via an amplitude transformer (11). According to the invention, the converter (9) or the amplitude transformer (11) is connected to the lateral surface of the sonotrode.