Ultrasonic Machining Calibration Using Component Identifiers
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Solution Overview
Problem
Ultrasonic processing devices face calibration challenges due to manufacturing tolerances, requiring complex measurements and initial weld seam assessment, which slows down the process and indirectly accounts for component tolerances, leading to inefficiencies.
Innovation Solution
An ultrasonic processing device with an identifier for each component, allowing for quick calibration to a target operating state without measurements, using an input interface and computing arrangement to adjust parameters based on the identifier, such as an RFID chip, smart code, or USB stick, ensuring accurate resonance frequency and amplitude settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex measurements are performed during calibration to account for manufacturing tolerances, then calibration accuracy is improved, but calibration time increases
Solution Approach 1:
The patent applies preliminary action by pre-measuring and storing individual component parameters (mass, dimensions, material properties) during component manufacturing. These parameters are saved in storage units associated with each component. During calibration, the system retrieves these pre-stored parameters instead of performing new measurements, thereby maintaining calibration accuracy while significantly reducing calibration time.
2Measurement precision
If initial weld seam quality assessment by person is performed to adjust welding parameters, then parameter adjustment accuracy is improved, but process automation is reduced
Solution Approach 1:
The patent implements feedback by using sensors to automatically detect weld seam quality parameters during the welding process. The control system receives this sensor data and automatically adjusts welding parameters based on the detected quality metrics, eliminating the need for manual assessment while maintaining or improving adjustment accuracy through consistent, objective measurements.
Solution Approach 2:
The patent replaces the manual visual assessment mechanism with an automated sensor-based detection system. The sensors electronically measure weld seam properties and transmit this information to the control system, which then automatically adjusts parameters, substituting human judgment with automated electronic measurement and control.
3Productivity
If component identifiers with individual parameters are read and used for adjustment, then calibration speed is improved, but device complexity increases
Solution Approach 1:
The patent applies copying by creating digital replicas of component parameters through identifiers (such as RFID tags, barcodes, or data storage units) attached to or associated with each component. These identifiers contain copied information about the component's individual parameters (mass, dimensions, material properties). The system reads these copied data representations instead of physically measuring each component, thereby increasing calibration speed while managing complexity through standardized data storage and retrieval mechanisms.
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 rapid and accurate calibration of ultrasonic processing devices by directly accounting for manufacturing tolerances, eliminating the need for on-site measurements and reducing calibration time, thus improving operational efficiency and handling of individual parameters.
Implementation Method 1
an ultrasonic processing device for processing a workpiece
Implementation Method 2
the device is operated in a desired operating state. This desired operating state is, in particular, a resonant vibration state
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The invention relates to an ultrasonic machining device (1) for machining a workpiece. At least one component, in particular all the components, selected from the group including a generator (11), converter (12), booster (13), sonotrode (14), HV cable (15), machine frame (16) and receiving device for the workpiece (17), is/are assigned an identifier (18). The identifier (18) characterises at least one individual parameter of the component, in particular a parameter influencing the process parameters, in particular the resonant frequency and the frequency bandwidth that can be used during operation and/or the amplitude of the device (1), in particular an electrical, acoustic or dimensional parameter. The device (1) is also assigned an input interface (19). The identifier (18) or data generated on the basis of the identifier (18) can be read in by means of the input interface (19). The device (1) is also assigned a data processing arrangement (20). By means of the data processing arrangement (20), based on the identifier (18) that has been read in or based on the data generated from the identifier (18), at least one parameter of the device (1) can be determined in such a way that the device (1) is operated in a target operating state. The target operating state is, for example, a resonant vibrating state.