Sonotrode Contact Detection Using Vibration Amplitude Changes
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Solution Overview
Problem
Existing methods for detecting contact-making or breaking between a sonotrode and a counterpart tool in ultrasonic vibration apparatuses are either not precise, require long lead times, or involve additional complexity and cost.
Innovation Solution
A method that records the time configuration of the vibration amplitude during a measurement time interval and determines whether contact-making or breaking occurred by comparing the recorded amplitude to a predetermined reference amplitude and tolerance range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensor means and electronic means are used to detect contact-making, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The sonotrode serves dual functions: it performs ultrasonic cutting while simultaneously acting as the sensing element for contact detection. The control unit monitors the sonotrode's own operational parameters (current, voltage, power consumption) to detect contact events, eliminating the need for separate sensors and electronic means.
Solution Approach 2:
The sonotrode is designed to perform multiple functions: it acts as both the cutting tool that generates ultrasonic vibrations and the sensing element that detects contact with the material or counter-element. The control unit also serves dual purposes by both controlling the sonotrode operation and monitoring contact events through the sonotrode's operational parameters.
2Measurement precision
If additional sensor means and electronic means are used to detect contact-making, then measurement precision is improved, but recording time increases
Solution Approach 1:
The sonotrode provides real-time self-monitoring through its operational parameters. Contact events are detected continuously during operation without requiring separate sensing systems that would introduce additional processing delays, achieving both high precision and rapid response.
3Ease of operation
If predefined operating time or energy consumption is used to determine cutting completion, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The control unit continuously monitors the sonotrode's operational parameters and compares them against expected values. When contact is detected through deviations in current, voltage, or power consumption, the system provides immediate feedback to terminate the cutting operation, ensuring precise completion based on actual contact events rather than predetermined time or energy thresholds.
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 method allows for rapid detection of contact events with recording times of less than 1 ms, enabling faster reaction times and reducing wear on the sonotrode and counterpart tool.
Implementation Method 1
a sonotrode (4) which is caused to vibrate with a frequency f and a vibration amplitude A0
Implementation Method 2
a converter (2) having at least one piezoelectric element for converting a high-frequency electrical voltage into a mechanical vibration
Data Source
AI summary
The present invention concerns a method of detecting the making or breaking of contact of a sonotrode (4) which is caused to vibrate with a frequency f and a vibration amplitude A0 with a counterpart element (5). To provide a method with which contact-making or breaking of a sonotrode with a counterpart element can be particularly quickly and inexpensively detected it is proposed according to the invention that the method has the following steps: a) recording a time configuration of the vibration amplitude A0 (1) during a first measurement time interval ΔT, and b) determining from the time configuration of the vibration amplitude A0 (1) whether making or breaking of contact occurred within the measurement time interval ΔT.