Torsional Sonotrode Support at the Oscillation Node for Efficient Welding
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Solution Overview
Problem
Existing ultrasonic welding devices face issues where the position of the oscillation node is dependent on forces and torques acting on the sonotrode head, leading to unwanted removal of ultrasonic energy and temperature rise.
Innovation Solution
A device where the sonotrode head is supported in a region containing an oscillation node, with the supporting region and welding face aligned perpendicularly to the torsion axis, and a supporting pin or bore that penetrates the sonotrode head to minimize energy loss, allowing precise positioning and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the sonotrode head is supported at a location with minimum amplitude (zero point support), then ultrasonic energy removal is minimized, but the position of the oscillation node is dependent on forces and torques acting on the sonotrode head, leading to displacement of the oscillation node
Solution Approach 1:
The supporting device is designed with multiple supporting elements (at least two supporting elements arranged at different locations) instead of a single support point. This segmentation allows the support system to maintain the oscillation node position more reliably under varying forces and torques, as the distributed support structure reduces the displacement caused by external loads while minimizing ultrasonic energy removal.
2Adaptability or versatility
If the oscillation node position is dependent on forces and torques, then the supporting device can adapt to different welding conditions, but this leads to undesired removal of ultrasonic energy and temperature rise at the supporting device
Solution Approach 1:
The supporting device incorporates a dynamic support system where at least two supporting elements can be adjusted or positioned to optimize support under different welding conditions. This dynamic capability allows the device to maintain reliable oscillation node positioning while adapting to varying forces and torques during different welding operations, preventing excessive temperature rise at the support locations.
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 configuration maintains the position of the oscillation node independently of applied forces or torques, reducing ultrasonic energy loss and ensuring a higher energy efficiency for welding, while also enabling effective temperature control through integrated cooling or heating mechanisms.
Implementation Method 1
The sonotrode head (12) can be excited to perform torsional oscillations with regard to a torsion axis (T) by an oscillation generator (19)
Implementation Method 2
The supporting device (15) supports the sonotrode head (12) in a supporting region (16), which contains an oscillation node of the sonotrode head (12)
Data Source
AI summary
A device (10′) for welding components by ultrasound. The device (10′) comprises a sonotrode (11′) having a sonotrode head (12′) which can be excited by a vibration generator to produce torsion vibrations with respect to a torsion axis (T). At least one welding surface (14′) is arranged on the peripheral side on the sonotrode head (12′) with respect to the torsion axis (T). The device (10′) also comprises a support device (15′) which supports the sonotrode head (11′) in a support area (16′), which contains a vibration node of the sonotrode head (12′). The support area (16′) and the welding surface (14′) at least partially extend along a common plane (E) which extends perpendicular to the torsion axis (T). A device (10′) for welding components by ultrasound by using a temperature control device are also disclosed.