Sonotrode Support Element for Precise Ultrasonic Weld Alignment
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Solution Overview
Problem
Existing ultrasonic welding systems face challenges in achieving high-precision and quick adjustment of the sonotrode's sealing surfaces relative to the anvil, leading to disruptions in the machining process, especially when replacing the sonotrode, due to complex positioning requirements and significant wear on the sealing surfaces.
Innovation Solution
A support element is introduced that allows the sonotrode to be positioned with its support surface on corresponding surfaces, enabling axial positioning without hindering rotation, thus simplifying the alignment of the ultrasonic oscillation unit and reducing the influence on the ultrasonic vibration, while a holder with an angular positioning device ensures precise angular alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional ultrasonic welding systems are used, then the sealing surfaces of the sonotrode and anvil can be positioned, but the positioning is complex and requires specially trained personnel, leading to disruptive interruptions in the welding process
Solution Approach 1:
A support element with support surface is introduced as an intermediary component between the sonotrode and the holder. This support element provides a predefined support surface that simplifies the positioning operation by eliminating the need for complex alignment procedures, allowing operators to simply place the sonotrode on the support element to achieve precise positioning.
Solution Approach 2:
The support element is pre-positioned in the holder before the sonotrode is installed. This preliminary action establishes the correct positioning reference in advance, so that when the sonotrode is placed on the support element, the sealing surfaces are automatically aligned parallel to each other without requiring complex adjustment operations during the welding process.
2Reliability
If the sonotrode is frequently changed or reversed, then wear on sealing surfaces can be managed, but the sonotrode must be repositioned precisely parallel to the anvil after each change, causing disruptions in the welding process
Solution Approach 1:
The support element serves as a reusable intermediary that remains in the holder while the sonotrode is changed or reversed. This eliminates the need to reposition the sonotrode after each change, as the support element maintains the correct positioning reference, allowing operators to simply replace or reverse the sonotrode and it will automatically align with the anvil through the support element.
Solution Approach 2:
The support element is pre-installed in the holder with the correct positioning geometry. This preliminary setup ensures that any sonotrode placed on the support element will be automatically positioned with sealing surfaces parallel to the anvil, eliminating the need for time-consuming repositioning operations after sonotrode changes or reversals.
3Reliability
If high forces are exerted during metal welding, then welding quality can be achieved, but the ultrasonic vibration unit deflects, causing the sealing surface of the sonotrode to no longer be aligned exactly parallel to the sealing surface of the anvil
Solution Approach 1:
The support element provides a counterbalancing support structure that compensates for the deflection of the ultrasonic vibration unit under high welding forces. By providing additional structural support at the sonotrode position, the support element counteracts the bending moments that would otherwise cause misalignment between the sealing surfaces, maintaining parallel alignment even under high load conditions.
Solution Approach 2:
The support element introduces an additional dimensional reference (the support surface) that is independent of the ultrasonic vibration unit's structural integrity. This separate positioning reference plane ensures that alignment is maintained through a different geometric dimension, preventing deflection-induced misalignment of the sealing surfaces under high welding forces.
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 facilitates simple, high-precision axial and angular positioning of the ultrasonic oscillation unit, minimizing deflection and wear, thereby improving welding quality and reducing the risk of component damage.
Implementation Method 1
the support surfaces are designed such that, when in contact with each other, they prevent a relative movement of the sonotrode with respect to the support element in the direction of the longitudinal axis
Implementation Method 2
do not impede a rotation of the sonotrode about the longitudinal axis
Implementation Method 3
the ultrasonic oscillator 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 4
the ultrasonic oscillator unit can be brought into resonance with an ultrasonic oscillation in the direction of the longitudinal axis
Implementation Method 5
a support element for supporting a force applied to the sonotrode perpendicular to the longitudinal axis, wherein the sonotrode and the support element have corresponding support surfaces which come into contact with each other at least when a force is exerted on the sonotrode perpendicular to the longitudinal axis
Data Source
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AI summary
The invention relates to an ultrasonic welding system with an ultrasonic vibrating unit which has a sonotrode and a converter. The sonotrode and the converter are arranged next to each other along the longitudinal axis, and the ultrasonic vibrating unit can be brought to a state of resonance with an ultrasonic vibration with a wavelength λ in the direction of the longitudinal axis. The aim of the invention is to provide an ultrasonic welding system which allows a highly precise adjustment of the sealing surfaces of the sonotrode relative to the anvil in a quick and simple manner. According to the invention, this is achieved in that a support element is provided for supporting a force applied to the sonotrode perpendicularly to the longitudinal axis, wherein the sonotrode and the support element have mutually corresponding support surfaces which come into contact with each other at least when a force is exerted onto the sonotrode perpendicularly to the longitudinal axis, and the support surfaces are designed to prevent a relative movement between the sonotrode and the support element in the direction of the longitudinal axis when the support surfaces are in contact with each other and to not interfere with the rotation of the sonotrode about the longitudinal axis.