Ultrasonic Sonotrode Alignment via U-Shaped Bearing
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Solution Overview
Problem
Existing ultrasonic welding devices require complex adjustments for precise axial and radial alignment of the sonotrode, making the setup process cumbersome and less reproducible.
Innovation Solution
The sonotrode is supported through a flat section on the transverse leg and against the side limbs of a trapezoidal projection, allowing for simple radial and axial alignment, with a pressure element providing force for secure positioning, and is supported in vibration nodes near the welding area for stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional punctiform support and complex adjustment mechanisms are used, then alignment precision can be achieved, but device complexity and setup time increase significantly
Solution Approach 1:
The support structure is segmented into multiple functional elements: a flat support section for radial alignment, trapezoidal projection elements for axial alignment, and a pressure element for securing. This segmentation allows each element to perform a specific alignment function independently, achieving precise alignment without requiring a complex integrated adjustment mechanism.
Solution Approach 2:
The sonotrode automatically aligns itself with the support structure through the geometric constraints provided by the flat support section and trapezoidal projection. The design eliminates the need for external adjustment mechanisms by making the alignment process self-contained within the support-sonotrode interface.
2Manufacturing precision
If complex adjustment mechanisms are implemented, then alignment accuracy improves, but ease of operation deteriorates due to cumbersome setup procedures
Solution Approach 1:
The alignment system is designed to be self-aligning through the geometric constraints of the flat support section and trapezoidal projection. The sonotrode naturally positions itself correctly when inserted, eliminating the need for operators to perform complex manual adjustments while maintaining high alignment accuracy.
Solution Approach 2:
The trapezoidal projection with its asymmetric geometry provides unique alignment constraints that guide the sonotrode into the correct position. The asymmetric shape ensures that only one orientation fits properly, automatically establishing both radial and axial alignment without requiring symmetric adjustment mechanisms.
3Manufacturing precision
If multiple support points and adjustment elements are used, then positioning accuracy is maintained, but assembly and disassembly time increases
Solution Approach 1:
The support structure is divided into distinct functional segments (flat support section, trapezoidal projection, pressure element) that can be independently manufactured and assembled. This modular segmentation allows for rapid assembly by simply bringing the components together without requiring complex integration procedures, while each segment maintains its contribution to positioning accuracy.
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 easy and reproducible alignment of the sonotrode, simplifying the setup process and ensuring accurate positioning for high-quality welds without the need for complex adjustments.
Implementation Method 1
The bearing runs in the oscillation node of the sonotrode, i.e. at a distance of λ/4 from the welding area or an area running adjacent to it
Implementation Method 2
an ultrasonic welding device (10) with oscillator (12, 14, 16)
Data Source
AI summary
The invention relates to an ultrasonic welding device having an oscillator (100), comprising a sonotrode (116), which can be caused to oscillate with a wavelength λ and has at least one welding region (120, 168) in the vibration antinode of the sonotrode, wherein the sonotrode is supported at the vibration node of the sonotrode in a first bearing (130). In order to enable both a radial and an axial alignment of the sonotrode by means of measures that are simple in regard to design without expensive assembly measures being required, according to the invention the first bearing (130) has a projection (132), which has a U-shaped geometry in a section extending in a longitudinal direction of the sonotrode, which U-shaped geometry has side legs (136, 138) and a cross leg (140) that connects the side legs, the projection engages in a recess (140, 144) in the sonotrode (116) matched to the U-shaped geometry, the sonotrode is supported on the cross leg of the projection in a planar manner, and the sonotrode is axially aligned by means of at least one side leg of the projection.