Sonotrode Angular Positioning for Fast Precise Welding Alignment
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Solution Overview
Problem
Existing ultrasonic welding systems face challenges in achieving high-precision and rapid adjustment of the sealing surfaces of the sonotrode relative to the anvil, particularly when dealing with metal welding, where frequent replacement and precise alignment are necessary, often requiring specialized personnel and leading to disruptions in the machining process.
Innovation Solution
The ultrasonic welding system incorporates an angular positioning device that connects form-fittingly with the ultrasonic oscillating unit, preventing rotation about the longitudinal axis and allowing adjustment along it, with features like recesses and projections for precise alignment and a fine adjustment mechanism to ensure parallel alignment of the sealing surfaces without the need for additional rotation adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ultrasonic oscillating unit is frequently replaced or adjusted, then welding quality can be maintained, but the alignment process becomes time-consuming and requires specialized personnel
Solution Approach 1:
The angular positioning device with form-fitting connection (protrusions and recesses) pre-establishes the correct angular position of the ultrasonic oscillating unit relative to the holder. When the unit is mounted or replaced, the form-fitting connection automatically guides it into the correct angular position, eliminating the need for time-consuming manual alignment and specialized personnel intervention.
2Manufacturing precision
If manual alignment of sealing surfaces is performed, then parallel positioning can be achieved, but the process is complex and disruptive to machining
Solution Approach 1:
The form-fitting connection between the angular positioning device and the ultrasonic oscillating unit performs the alignment function automatically. The geometric constraints of the protrusions and recesses self-guide the sealing surfaces into parallel positioning without requiring external alignment tools or complex adjustment procedures, thereby simplifying the process while maintaining high precision.
3Duration of action of stationary object
If the sonotrode is rotated to use multiple sealing surfaces, then component life is extended, but re-alignment is required after each rotation
Solution Approach 1:
The angular positioning device pre-establishes multiple valid angular positions through its form-fitting connection design. When the sonotrode is rotated to use a different sealing surface, the form-fitting connection automatically guides it into the correct angular position corresponding to that sealing surface, eliminating the need for manual re-alignment and making the operation simple and quick.
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 solution enables simple, rapid, and high-precision alignment of the sonotrode and anvil sealing surfaces, reducing the need for specialized personnel and minimizing disruptions during the machining process, while also reducing wear on the sonotrode and preventing damage from bending moments.
Implementation Method 1
the ultrasonic oscillating unit can be brought into resonance with an ultrasonic oscillation in the direction of the longitudinal axis with a frequency f = v/λ
Implementation Method 2
the ultrasonic oscillating unit can be brought into resonance with an ultrasonic oscillation
Data Source
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AI summary
The invention relates to an ultrasonic welding system, comprising an ultrasonic oscillation unit, which has a sonotrode and a converter, the sonotrode and the converter being arranged next to one another along a longitudinal axis and the ultrasonic oscillation unit being able to be brought into resonance by means of an ultrasonic oscillation in the direction of the longitudinal axis with a wavelength λ/2, a retainer being provided retaining the ultrasonic oscillation unit. The aim of the invention is to provide an ultrasonic welding system that allows simple, quick and highly precise adjustment of the sealing surfaces of the sonotrode relative to the anvil. This aim is achieved, according to the invention, in that the retainer has an angular positioning device, the angular positioning device and the ultrasonic oscillation unit being designed in such a way that the angular positioning device and the ultrasonic oscillation unit can be interlockingly connected to one another such that rotation of the ultrasonic oscillation unit about the longitudinal axis is prevented by the interlocking connection and relative movement between the ultrasonic oscillation unit and the retainer in the direction of the longitudinal axis is not prevented.