Multistage Ultrasonic Splice Welding for Uniform Energy Distribution
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Solution Overview
Problem
Ultrasonic welding of splices with relatively large cross-sections faces challenges due to inhomogeneous energy distribution and potential damage to conductors, particularly in high-current applications.
Innovation Solution
A two-stage ultrasonic welding process using an adjustable compaction chamber with a sonotrode, anvil, and lateral elements to ensure uniform energy distribution and prevent conductor damage, achieved by varying the chamber width with a predetermined tolerance value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-stage ultrasonic welding process is used for splices with relatively large cross-sections, then the welding process is simple and quick, but the ultrasonic energy distribution becomes inhomogeneous and conductor damage occurs
Solution Approach 1:
The welding process is divided into multiple stages, with each stage welding a subset of conductors. This segmentation allows ultrasonic energy to be distributed more uniformly across smaller groups of conductors in each stage, preventing the inhomogeneous energy distribution that occurs when welding all conductors simultaneously in a single stage.
Solution Approach 2:
Conductors are arranged in a specific preliminary configuration before welding, with some conductors positioned to be welded first in the first stage. This preliminary arrangement ensures that ultrasonic energy is introduced uniformly to the conductors being welded at each stage, preventing damage to conductors that would occur with simultaneous welding of all conductors.
2Manufacturing precision
If a two-stage ultrasonic welding process is used for splices with relatively large cross-sections, then energy distribution uniformity improves, but the welding process complexity increases
Solution Approach 1:
The compaction chamber width is made dynamically adjustable between welding stages. The width is varied by a predetermined tolerance value to optimize the arrangement of conductors for each specific welding stage, ensuring uniform energy distribution while managing process complexity through controlled dynamic adjustment.
Solution Approach 2:
Physical parameters of the compaction chamber (specifically width) are changed between welding stages. The width parameter is varied by a predetermined tolerance value to accommodate different conductor arrangements in each stage, achieving uniform energy distribution without requiring complex additional equipment.
3Ease of operation
If the compaction chamber width is kept constant during welding, then the device operation is simple, but conductor breaks and discolorations occur due to inhomogeneous energy distribution
Solution Approach 1:
The compaction chamber width parameter is changed by a predetermined tolerance value between welding stages. This parameter change allows optimal arrangement of conductors for uniform energy distribution in each stage, preventing conductor breaks and discolorations while maintaining relatively simple device operation through controlled parameter variation.
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 method produces consistently high-quality splices with reduced conductor breaks and discolorations, ensuring uniform connector strength and ease of processing.
Implementation Method 1
a sonotrode (102) for generating ultrasonic vibrations... performing the first welding operation by activating the sonotrode and compressing the first conductor portions (112) between the sonotrode (102) and the anvil (104), the first conductor portions (112) being welded together
Implementation Method 2
compressing the first conductor portions (112) between the sonotrode (102) and the anvil (104)... compressing the first splice (300) and the second conductor portion (400) between the sonotrode (102) and the anvil (104)
Data Source
AI summary
A method is described for welding a splice by way of an ultrasonic welding device, the ultrasonic welding device having a sonotrode for generating ultrasonic vibrations, an anvil, a first lateral element, a second lateral element and a compaction chamber, the height of which is adjustable by varying a distance between the sonotrode and the anvil and the width of which is adjustable by varying a distance between the first lateral element and the second lateral element.