Ultrasonic Cable Tie Welding with Feedback Energy Control
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Solution Overview
Problem
Automated ultrasonic welding of cable ties faces challenges in achieving repeatable weld quality due to variations in clamping force and weld energy, which can compromise the integrity of cable bundles and fail to meet regulatory standards like UL and IEC 62275.
Innovation Solution
A feedback control system that adjusts the clamping force and ultrasonic welding energy by using a reference power curve and sensor feedback to ensure consistent weld quality, comprising an ultrasonic weld generator, applicator tool with a weld horn and pivotal arms, and a controller that adjusts the welding process based on measured clamping force and estimated weld energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical locking features with housing are used to secure cable ties, then the cable tie can be fastened in a closed position, but the housing creates a protrusion that rubs against and deteriorates the adjacent insulation of cables
Solution Approach 1:
The patent removes the traditional housing component from the cable tie design. Instead of using a housing to secure the cable tie in the closed position, the invention uses a tab that is ultrasonically welded directly to the cable tie body, eliminating the protruding housing that causes insulation deterioration while maintaining the fastening function.
Solution Approach 2:
The patent replaces the mechanical locking system with housing and pawl-serration engagement with an ultrasonic welding system. The tab is secured to the cable tie body through ultrasonic welding, substituting the mechanical housing-based locking mechanism with a direct welding process that eliminates the harmful protrusion.
2Object-affected harmful factors
If ultrasonic welding is used to secure cable ties, then the housing protrusion problem is eliminated, but repeatable weld quality is difficult to achieve due to variations in clamping force and weld energy
Solution Approach 1:
The patent incorporates a feedback control system that includes a force sensor to measure clamping force and a power sensor to monitor weld energy in real-time during the ultrasonic welding process. These sensors provide feedback to a controller that adjusts welding parameters to maintain consistent weld quality despite variations in material properties or positioning.
Solution Approach 2:
The patent uses a feedback control system that dynamically adjusts welding parameters (clamping force, weld energy, welding time) based on real-time sensor measurements. This allows the system to compensate for variations in material properties, positioning, or environmental conditions to achieve repeatable weld quality.
3Manufacturing precision
If feedback control system with sensors is implemented, then weld quality repeatability is improved, but device complexity increases
Solution Approach 1:
The patent integrates force sensors and power sensors directly into the welding tool, allowing real-time measurement and control of clamping force and weld energy. The controller processes sensor data and adjusts welding parameters automatically, providing feedback control that ensures repeatable weld quality without requiring complex external monitoring systems.
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
The system ensures repeatable weld quality by maintaining consistent clamping force and weld energy, improving the integrity of cable ties and compliance with regulatory standards by minimizing waste and optimizing the welding process.
Implementation Method 1
an ultrasonic weld generator can provide an ultrasonic wave to the applicator tool for the ultrasonic welding of the object
Data Source
AI summary
A feedback control system for use with ultrasonic welding. A weld energy set point and/or a reference power curve are used by a controller to provide a power supply voltage set point and a power supply frequency set point for the power that is to be drawn by an ultrasonic weld generator. Information regarding the actual voltage and/or frequency of the drawn electrical power, and/or the frequency and magnitude of an ultrasonic wave transmitted from the generator to an applicator tool used to weld an object can be utilized by an estimator to estimate the weld energy dissipated at the weld site and/or generate a power curve for the welding operation. Using information from the estimator, the controller can determine adjustments for variables for the current and/or future welding operations. Further, welding may not commence until a clamping force exerted on the object satisfies a clamping force set point.