Ultrasonic Lead Wire Joining With Dancer Roller Tension Control
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Solution Overview
Problem
Conventional ultrasonic joining apparatuses struggle to accurately adjust tension on lead wires during the joining process, leading to inconsistent and inaccurate joining of lead wires to substrates.
Innovation Solution
The ultrasonic joining apparatus incorporates a tension adjustment mechanism with a dancer roller that can be moved up and down, maintaining contact with the lead wire to adjust tension. This mechanism is controlled by a controller that sets the tension adjustment range and positions, ensuring stable tension during the joining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional lead wire drawing apparatus is used for tension adjustment, then the apparatus structure is simple, but the tension adjustment cannot be accurately fitted to the drawing operation and ultrasonic joining processing
Solution Approach 1:
The tension adjustment mechanism uses a dancer roller that can dynamically move up and down within a tension adjustment range, allowing the system to adapt to varying tension requirements during different stages of the ultrasonic joining process. This dynamic adjustment capability enables accurate tension control that matches the actual operation contents, resolving the contradiction between simple structure and precise tension adjustment.
2Reliability
If the dancer roller is positioned for tension adjustment processing, then tension control is improved, but the mechanism cannot perform during preparatory operations
Solution Approach 1:
The dancer roller is designed to be movable between different positions: a first position for tension adjustment processing during ultrasonic joining, and a second position for preparatory operations. This dynamic repositioning capability allows the mechanism to adapt to different operational states, providing reliable tension control when needed while remaining flexible for various operational phases.
Solution Approach 2:
The mechanism allows the dancer roller to be positioned in advance at a second position during preparatory operations, before the actual ultrasonic joining begins. This preliminary positioning ensures the mechanism is ready for tension adjustment when needed, without interfering with preparatory steps, thus maintaining both reliability and adaptability.
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 apparatus achieves stable and accurate tension control on the lead wire, ensuring consistent and precise joining of the lead wire to the substrate, even during the ultrasonic joining process.
Implementation Method 1
an ultrasonic joining head performing ultrasonic joining processing on the lead wire disposed on a substrate to join the lead wire to the substrate
Data Source
AI summary
In an ultrasonic joining apparatus according to the present disclosure, an ultrasonic joining apparatus control board controls an operation of a lead set unit and a tension adjustment unit including a dancer roller to perform joining tension control processing. The joining tension control processing includes steps of: making a lead wire housing mechanism perform a rewinding driving of rewinding a lead wire in a lead cassette when the dancer roller reaches a lower limit adjustment position in a tension adjustment range; and making the lead wire housing mechanism perform a delivery driving of sending out the lead wire from the lead cassette when the dancer roller reaches an upper limit adjustment position in the tension adjustment range.