Ultrasonic Welding Holder for Fast Sonotrode Alignment and Replacement
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Solution Overview
Problem
Existing ultrasonic welding installations face challenges in achieving precise and laborious adjustment and replacement of ultrasonic vibration units, leading to troublesome interruptions and wear on sealing surfaces, particularly in metal welding, where frequent replacement and precise parallel positioning of sonotrode and anvil sealing surfaces are necessary for high weld quality.
Innovation Solution
A holder with a clamping device that allows for simple adjustment and replacement of the ultrasonic vibration unit, featuring a reciprocable clamping mechanism with multiple holding points and a sleeve design that securely holds the unit without causing plastic deformation, along with a positively locking connection between the sonotrode and converter, enabling easy rotation and axial positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sonotrode is frequently replaced or turned to orient another sealing surface parallel to the counterpart tool, then the weld quality can be maintained, but complete dismantling of the ultrasonic vibration unit is necessary which is time-consuming and requires fresh adjustment
Solution Approach 1:
The holder is divided into a stationary part and a rotatable part that can be independently adjusted. The ultrasonic vibration unit is segmented from the holder structure, allowing it to be rotated or replaced without complete dismantling. The clamping device is separated into movable clamping elements that can release the vibration unit for quick replacement.
Solution Approach 2:
The holder incorporates a rotatable part that can dynamically adjust the angular position of the ultrasonic vibration unit relative to the stationary part. This dynamic adjustment mechanism allows the sealing surface to be reoriented without complete disassembly, reducing replacement time while maintaining weld quality.
2Reliability
If the holder has a complicated structure to support the ultrasonic vibration unit, then the unit can be held securely, but simple quick dismantling of the ultrasonic vibration unit is not permitted
Solution Approach 1:
The holder structure is segmented into modular components: a stationary part, a rotatable part, and an independently operable clamping device. This segmentation allows the clamping mechanism to be operated separately from the rotational adjustment mechanism, enabling simple quick dismantling while maintaining secure holding through the robust stationary-rotatable connection.
Solution Approach 2:
The clamping device is designed with preliminary positioning features that guide the ultrasonic vibration unit into the correct position before clamping. This preliminary action ensures secure holding is achieved automatically when the clamping device is engaged, eliminating the need for complex manual alignment procedures during dismantling.
3Manufacturing precision
If the sealing surfaces of the sonotrode and anvil are positioned very precisely parallel to each other, then high weld quality is achieved, but the parallel positioning is highly complicated and laborious
Solution Approach 1:
The holder provides dynamic angular adjustment capability through its rotatable part, allowing the sealing surface of the ultrasonic vibration unit to be precisely oriented parallel to the anvil sealing surface. This mechanical degree of freedom simplifies the positioning process compared to fixed-structure alternatives, as the parallel alignment can be achieved through controlled rotation rather than complex multi-axis adjustment.
Solution Approach 2:
The holder structure incorporates self-aligning features that automatically guide the ultrasonic vibration unit into the correct parallel position relative to the anvil. This self-service mechanism reduces the complexity of manual positioning operations, as the system partially performs the alignment function automatically when components are assembled.
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
Facilitates easy and precise adjustment and replacement of the ultrasonic vibration unit, reducing wear on sealing surfaces and minimizing interruptions, thereby improving weld quality and reducing the complexity of the replacement process.
Implementation Method 1
the ultrasonic vibration unit can be caused to resonate by means of an ultrasonic vibration in the direction of the longitudinal axis at a frequency f=v/λ
Implementation Method 2
the ultrasonic vibration unit can be caused to resonate by means of an ultrasonic vibration
Implementation Method 3
the clamping device comes into contact with the ultrasonic vibration unit and exerts a force on same so that the ultrasonic vibration unit is held
Data Source
AI summary
The present invention concerns an ultrasonic welding installation comprising an ultrasonic vibration unit having a sonotrode and a converter, wherein the sonotrode and the converter are arranged in mutually adjacent relationship along a longitudinal axis and the ultrasonic vibration unit can be caused to resonate with an ultrasonic vibration in the direction of the longitudinal axis with a wavelength λ, wherein there can be provided an amplitude transformer arranged between the sonotrode and the converter, wherein there is provided a holder for holding the ultrasonic vibration unit. To provide an ultrasonic welding installation having a holder which allows simple adjustment of the ultrasonic vibration unit and simple replacement thereof it is proposed according to the invention that the holder has a clamping device which is reciprocable between an opened position in which the ultrasonic vibration unit can be removed from the holder and a closed position in which the clamping device comes into contact with the ultrasonic vibration unit and exerts a force on same so that the ultrasonic vibration unit is held.