Segmented Ultrasonic Welding Head for Flexible Acoustic Layouts
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Solution Overview
Problem
Existing welding head assemblies in ultrasonic welding are limited in structural variation due to the need for a small distance between components, restricting their ability to meet diverse welding requirements.
Innovation Solution
A welding head assembly design where the vibrating rod is separated into two pieces by an acoustic rod, with the acoustic rod, first vibrating rod, and connecting member formed as a single piece, allowing for various configurations and improved adaptability to different welding scenes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding head part is designed with a small distance between the first part and the second part to meet acoustic requirements, then the acoustic performance is improved, but the structural variation of the welding head part is limited
Solution Approach 1:
The vibrating rod is segmented into a first vibrating rod and a second vibrating rod that are separately connected to the acoustic rod, allowing independent structural design and variation while maintaining acoustic performance requirements
Solution Approach 2:
The design transitions from a planar symmetric arrangement to a three-dimensional configuration where the first and second vibrating rods can be positioned at different locations and orientations relative to the acoustic rod, enabling structural variation without compromising acoustic performance
2Reliability
If the first part and the second part are connected symmetrically about the center to ensure acoustic requirements, then the acoustic performance is improved, but the adaptability to various welding requirements is limited
Solution Approach 1:
The design adopts asymmetric configuration where the first and second vibrating rods are not required to be symmetric about the center, allowing the welding head to be adapted to different welding scenarios with varying geometric requirements while maintaining acoustic performance through proper nodal point positioning
3Device complexity
If the vibrating rod is kept as a single piece to simplify structure, then the device complexity is reduced, but the ability to meet various welding requirements is limited
Solution Approach 1:
The vibrating rod is divided into separate components (first vibrating rod and second vibrating rod) that can be independently designed and configured for different welding applications, increasing adaptability while maintaining relatively simple individual structures
Solution Approach 2:
The acoustic rod serves as a universal connection element that can interface with different configurations of vibrating rods, allowing the same acoustic rod design to support multiple welding head configurations for various welding requirements
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
Ensures good welding quality and expanded applicability by reducing assembly defects and enabling the welding head to meet various welding requirements and scenes, enhancing the suitability of ultrasonic welding.
Implementation Method 1
convert utility-frequency alternating current into high-frequency electric energy through an ultrasonic generator, and the converted high-frequency electric energy is then converted into mechanical motion with a same frequency through a transducer
Implementation Method 2
vibration energy received by the welding head is transmitted to a welding joint portion of a workpiece to be welded, in which area the vibration energy is converted into heat energy by friction for welding
Data Source
AI summary
The objective of the present invention is to provide a welding head assembly that can meet various welding requirements. The welding head assembly for ultrasonic welding to realize the objective mentioned above, comprising an acoustic rod, a vibrating rod and a connecting member, the vibrating rod is separated into two pieces, thereby separated into a first vibrating rod and a second vibrating rod by the acoustic rod, the first vibrating rod is connected with the acoustic rod and the connecting member, one end of the second vibrating rod is connected with the acoustic rod, and the other end of the second vibrating rod is configured to be a welding head working portion; wherein, the acoustic rod, the first vibrating rod and the connecting member are integrally formed as one piece.