Rotating Sonotrode Assembly for Portable Ultrasonic Metal Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 20kHz UAM welding assemblies are too large, heavy, and power-hungry, limiting their accessibility and practicality for off-grid or remote applications.
Innovation Solution
A scaled-down ultrasonic welding assembly with low-friction bearings and a rotating sonotrode design, allowing high loads and reduced power consumption, featuring a sonotrode with nodal regions supported by frictionless bearings and a diaphragm spring system for axial rotation and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a 20kHz UAM welding assembly is designed to deliver high power (10,000 W) and high load capacity (>1000 pounds), then welding effectiveness is improved, but the system becomes large, heavy, and bulky, limiting accessibility and portability
Solution Approach 1:
The patent changes the operating frequency parameter from conventional 20kHz to a higher frequency range (30-50kHz). This parameter change allows the system to achieve the same welding power and load capacity with a significantly reduced assembly size and weight, resolving the contradiction between high power delivery and portability
Solution Approach 2:
The patent introduces a rotating sonotrode design that rotates about its longitudinal axis during welding. This dynamic element distributes wear evenly across the sonotrode surface, enables continuous welding operation, and allows for more compact assembly design while maintaining high power delivery capability
2Productivity
If a 20kHz UAM welding assembly is designed with high power capacity (10,000 W), then deposition rate is improved, but power consumption becomes excessive for off-grid or remote applications
Solution Approach 1:
By increasing the operating frequency from 20kHz to 30-50kHz, the patent achieves higher welding efficiency and deposition rates at lower power consumption. The higher frequency enables more effective ultrasonic energy transmission to the workpiece, improving productivity while reducing the total power required from the generator
Solution Approach 2:
The patent optimizes the mechanical vibration characteristics through higher frequency operation and rotating sonotrode design. This creates more effective welding action with reduced energy loss, achieving high deposition rates with lower overall power consumption suitable for off-grid applications
3Strength
If a 20kHz UAM welding assembly is designed with high load capacity (>1000 pounds), then weld strength is improved, but the system requires large, heavy, and bulky equipment
Solution Approach 1:
The patent uses higher operating frequency (30-50kHz) to achieve more efficient energy transmission and better welding performance at lower loads. This allows the system to produce strong welds with a more compact assembly, eliminating the need for large, heavy equipment while maintaining weld strength
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 welding of metals in off-grid environments with reduced size and power requirements, facilitating portable and high-power ultrasonic metal welding.
Implementation Method 1
an ultrasonic stack that includes a converter or piezoelectric transducer for converting the electrical signal into a mechanical vibration
Implementation Method 2
high-frequency (e.g., >20 kHz) to merge layers of metal drawn from featureless foil stock... high-frequency (e.g., 20kHz) ultrasonic vibrations are locally applied to metal foils, which are held together under pressure, to create a solid-state weld
Implementation Method 3
a first frictionless bearing assembly positioned around the first nodal region of the sonotrode... a second frictionless bearing assembly positioned around the second nodal region of the sonotrode
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.