Dual-Axis Rotating Sonotrode for Ultrasonic Welding
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Solution Overview
Problem
Ultrasonic welding machines with existing tools, such as sonotrodes and backplate electrodes, have limitations in optimizing the utilization of working surfaces, leading to reduced service life and inefficient operation.
Innovation Solution
The tool, specifically a sonotrode and backplate electrode, is designed to be rotated around both the longitudinal and transverse axes, allowing for optimal alignment and utilization of working surfaces, effectively doubling their functionality and extending the service life by ensuring uniform wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tool is rotated only around the longitudinal axis, then different working surfaces can be aligned on compression chambers with different cross sections, but the utilization of each working surface is not optimized
Solution Approach 1:
The tool is made dynamically adjustable by enabling rotation around both the longitudinal axis and the transverse axis. This dynamic positioning capability allows any working surface to be selectively aligned with any compression chamber, optimizing surface utilization while maintaining versatility for different chamber cross sections
Solution Approach 2:
The invention adds a second rotational degree of freedom (transverse axis) to the existing first degree of freedom (longitudinal axis). This dimensional expansion in the rotation space enables comprehensive alignment options, allowing each working surface to serve multiple compression chambers that would otherwise require separate tools
2Adaptability or versatility
If multiple working surfaces are provided on the tool, then different compression chambers can be accommodated, but the service life of the tool is reduced due to wear on multiple surfaces
Solution Approach 1:
Each working surface on the tool is designed to be multi-functional through dual-axis rotation. A single surface can be repeatedly used across different compression chambers by rotating the tool into the appropriate orientation, rather than requiring dedicated surfaces for each chamber type. This universality reduces the number of actively used surfaces while maintaining multi-chamber compatibility
Solution Approach 2:
The invention enables recovery and reuse of working surfaces by rotating the tool to bring fresh surfaces into contact with compression chambers. Instead of progressing linearly through multiple worn surfaces, the dual-axis rotation allows selective reuse of less-worn surfaces, effectively recovering tool life by optimizing which surfaces are activated at any given time
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 enables each working surface to function as two, resulting in improved operational efficiency and extended service life of the ultrasonic welding machine, particularly suitable for welding and separating pipes in refrigeration sets.
Implementation Method 1
a sonotrode with four working surfaces, and an anvil with four working surfaces... the sonotrode generates ultrasonic vibrations
Data Source
AI summary
An ultrasonic welding machine having a tool in the form of, for example, a sonotrode. In order to allow for an optimal utilization of the working surfaces of the sonotrode, it is proposed to move or mount the sonotrode in a desired position with respect to the element that connects the ultrasonic welding machine to the sonotrode by rotating the sonotrode around its longitudinal axis as well as a transverse axis running perpendicular thereto.