Spherical Workpiece Holder for Plane-Parallel Welding Alignment
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Solution Overview
Problem
Existing workpiece holders require complex and expensive alignment processes, especially for precise plane-parallel alignment of plastic components in ultrasonic welding, and are not efficiently adaptable for other processing devices like presses or punches.
Innovation Solution
A workpiece holder with a receiving element and base element connected by a bearing device featuring concentric spherical surfaces and equidistantly arranged balls, allowing for single-axis alignment and automatic plane-parallel positioning of workpieces, along with a fixing element for secure placement during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional workpiece holders are used for precise alignment of workpieces in ultrasonic welding, then alignment precision can be achieved, but the device complexity and cost increase significantly due to required multi-axis alignment mechanisms
Solution Approach 1:
The patent applies spherical surfaces to the bearing shells, allowing the receiving element to rotate and align automatically through spherical geometry rather than requiring complex multi-axis alignment mechanisms. The spherical bearing surfaces enable automatic orientation of the workpiece in space with a single degree of freedom rotation.
Solution Approach 2:
The workpiece holder enables self-alignment through the spherical bearing mechanism, where the receiving element automatically orients itself relative to the base element without requiring external alignment devices or complex control systems. The spherical geometry provides inherent alignment capability.
2Manufacturing precision
If conventional workpiece holders with multi-axis alignment are used, then precise positioning is possible, but the ease of operation deteriorates due to complex alignment procedures
Solution Approach 1:
The spherical bearing surfaces replace complex multi-axis alignment mechanisms with a simple spherical rotation joint, allowing the operator to achieve precise positioning through a single rotational degree of freedom rather than manipulating multiple alignment axes.
Solution Approach 2:
The spherical bearing mechanism enables the receiving element to self-align automatically, reducing the operational complexity from multi-axis manual alignment to a simple single-axis rotation operation.
3Manufacturing precision
If conventional workpiece holders are designed for welding applications, then welding precision is maintained, but the adaptability to other processing devices like presses or punches deteriorates
Solution Approach 1:
The workpiece holder design with spherical bearings and a base element provides a universal mounting interface that can be adapted to different processing devices including ultrasonic welding machines, presses, and punches, while maintaining precise positioning capability across all applications.
Solution Approach 2:
The workpiece holder is segmented into a base element and a receiving element connected by spherical bearings, allowing the receiving element to be adapted for different workpiece types and processing applications while maintaining the precise alignment capability through the spherical connection mechanism.
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 precise, cost-effective alignment and secure fixation of workpieces in ultrasonic welding and other processing devices, reducing the need for complex multi-axis alignment and minimizing mechanical adjustments during the welding process.
Implementation Method 1
both bearing shells have a spherical surface. This makes it possible, with the aid of the workpiece holder according to the invention, to align the at least one workpiece supported by the receiving element in space
Implementation Method 2
balls are arranged between the two bearing shells
Data Source
Figure 1
AI summary
A workpiece receptacle, in particular for an ultrasonic welding device has a receiving element (10) for receiving a workpiece. The receiving element (10) can be moved in relation to a base element (16). A bearing device (20) is disposed between the receiving element (10) and the base element (16) for this purpose. The bearing device (20) has spherical surfaces (28, 32) lying opposite one another.