Multi-Axis Ultrasonic Weld Head for Flexible Workpiece Joining
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Solution Overview
Problem
Existing ultrasonic welding technologies are limited in cost, operational efficiency, flexibility, and portability, failing to meet market demands for diverse applications.
Innovation Solution
An ultrasonic welding system with a moveable weld head assembly and sonotrode capable of operating at specific bond forces and amplitudes, combined with horizontal and rotational motion, for efficient welding of various workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing ultrasonic welding technology is used, then welding capability is provided, but cost, operational efficiency, flexibility, and portability fail to meet market demands
Solution Approach 1:
The weld head assembly is made dynamically movable along multiple horizontal axes (X, Y, and rotational) rather than being fixed in a single position. This dynamic positioning capability allows the same welding system to adapt to different workpiece configurations, sizes, and welding locations, significantly improving flexibility without requiring multiple separate welding stations
Solution Approach 2:
The welding system is designed with a universal weld head assembly that can perform welding operations on various workpiece types and configurations through its multi-axis movement capability. A single system can handle diverse welding applications by repositioning the sonotrode to different locations and orientations, eliminating the need for multiple specialized welding devices
2Adaptability or versatility
If wire bonding is used for joining materials, then interconnections are formed, but the technology is limited to relatively low energy levels and specific applications
Solution Approach 1:
The system changes the energy parameters by utilizing ultrasonic vibration energy at controlled amplitudes (5-150 microns) and bond forces (5-500 kg) to achieve welding of diverse materials. This parameter adjustment allows transition from low-energy wire bonding to higher-energy welding applications while maintaining precision control, expanding the range of joinable materials and applications
3Productivity
If ultrasonic welding is performed with fixed sonotrode position, then welding operation is simple, but flexibility and adaptability to different workpieces are limited
Solution Approach 1:
The weld head assembly incorporates dynamic positioning mechanisms that allow movement along X and Y horizontal axes plus rotational capability. This enables the system to efficiently access different welding locations on various workpiece configurations while maintaining precise control, achieving both high productivity and workpiece adaptability through coordinated multi-axis motion
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
Enables efficient volume production and flexible welding operations, enhancing operational efficiency and adaptability across different materials and configurations.
Implementation Method 1
Ultrasonic welding may use an ultrasonic converter (e.g., carrying a sonotrode) for converting electrical energy into mechanical movement/scrub (e.g., linear movement/scrub, torsional movement/scrub, etc.)
Implementation Method 2
Ultrasonic welding is also a widely used technology
Data Source
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Figure 3A
AI summary
An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The weld head assembly is moveable along a plurality of substantially horizontal axes. The sonotrode is configured to operate during a welding operation at a bond force of between 5-500 kg, and with a sonotrode tip motion amplitude of between 5-150 microns.