Multipoint Ultrasonic Welding Control for Low-Noise Probe Switching
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Solution Overview
Problem
The complexity and cost associated with sharing a power supply among multiple ultrasonic welding probes in manufacturing environments, due to the need for custom cables and shielding to protect against electronic noise, lead to increased manufacturing and maintenance challenges.
Innovation Solution
Implementing a multipoint controller unit with Ethernet communication and multi-channel analog inputs, which decouples power and communication ports, allowing for the use of off-the-shelf RJ-45 couplers and shielded CAT-5 cables, reducing wiring costs and noise susceptibility, and enabling faster processing of distance information for improved welding accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom cables and shielding are used to protect against electronic noise when sharing a power supply among multiple probes, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an intermediary device (the multipoint controller with Ethernet communication) that mediates between the power supply and multiple probes. This intermediary handles the complex shielding and noise protection requirements centrally, allowing simpler connection cables to be used at each probe interface while maintaining overall system reliability through the controller's built-in interference protection capabilities.
2Reliability
If custom cables and shielding are used to protect against electronic noise, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The multipoint controller provides universal connectivity for multiple probes through standard Ethernet interfaces. A single controller unit can serve multiple probes simultaneously, eliminating the need for each probe to have its own custom-shielded cable connection to the power supply. This multi-functional approach consolidates the noise protection infrastructure into one device, reducing overall manufacturing costs while maintaining reliability.
3Ease of manufacture
If decoupled power and communication ports with Ethernet communication are used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent replaces the traditional mechanical/electrical direct connection system with an Ethernet-based communication system. Instead of using complex custom-shielded cables for both power and data, the system uses standard Ethernet cables for communication and separate power connections, substituting the need for intricately designed multi-functional cables with simpler, standardized components that are easier to manufacture and assemble.
Data Source
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AI summary
A system for providing power to more than one ultrasonic welding probe from M power supplies includes N multipoint units and a base. Each of the N multipoint units includes: a housing, a plurality of analog or digital inputs configured to carry distance information regarding probe distance of a plurality of ultrasonic welding probes, a dedicated high voltage input connector connectable via a high voltage cable to a dedicated high voltage output connector of one of the M power supplies, and a microcontroller. The microcontroller is configured to: direct power from the dedicated high voltage input connector to a corresponding one of the plurality of ultrasonic welding probes, and sample the distance information of the plurality of ultrasonic welding probes at a rate of at least once per millisecond. The base houses the M power supplies, wherein M and N are both integers greater than or equal to 1.