Ultrasonic Welding Horn Mounting for Precise Gap Alignment
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Solution Overview
Problem
In ultrasonic welding, existing systems lack precise control over the gap between the horn and anvil, which affects the physical characteristics of the welded product, and do not adequately limit degrees of freedom to ensure consistent alignment and adjustment of the horn's longitudinal axis with the anvil's.
Innovation Solution
A mounting system that restricts the horn and anvil to specific degrees of freedom, allowing only two additional freedoms: translational motion perpendicular to the axis and rotational motion about a second axis perpendicular to the first, enabling precise adjustment of the gap and alignment between the horn and anvil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the horn and anvil are allowed to move freely in all directions, then the system has high adaptability to different workpiece positions, but the gap control precision and alignment consistency deteriorate
Solution Approach 1:
The mounting system segments the degrees of freedom into two categories: constrained movements (prevented by the mounting system) and permitted movements (rotational adjustment about the longitudinal axis and translational adjustment perpendicular to the axis). This segmentation allows precise gap control while maintaining necessary positioning flexibility.
Solution Approach 2:
The mounting system provides dynamic adjustability by allowing rotational movement about the longitudinal axis and translational movement perpendicular to the axis, enabling the horn to be dynamically repositioned to achieve the desired gap and parallel alignment while maintaining control precision during operation.
2Manufacturing precision
If multiple degrees of freedom are allowed for the horn, then the alignment can be adjusted to match various anvil positions, but the consistency of parallel alignment between horn and anvil axes deteriorates
Solution Approach 1:
The mounting system segments alignment adjustments into two distinct functions: rotational adjustment about the longitudinal axis for aligning the horn axis parallel to the anvil axis, and translational adjustment perpendicular to the axis for positioning the horn at the desired gap distance. This segmentation ensures consistent parallel alignment while maintaining ease of operation.
Solution Approach 2:
The mounting system provides local quality by allowing rotational adjustment specifically about the longitudinal axis to achieve parallel alignment, while preventing other rotational movements that would compromise alignment consistency. This localized freedom of movement ensures the horn axis remains parallel to the anvil axis during operation.
3Manufacturing precision
If the horn mounting system allows free movement in all directions, then installation and repositioning are easier, but the gap between horn and anvil cannot be precisely controlled
Solution Approach 1:
The mounting system provides dynamic adjustability during installation by allowing translational movement perpendicular to the longitudinal axis, enabling easy repositioning of the horn to achieve the desired gap distance. Once installed, the system maintains precise gap control by constraining movements in other directions while permitting controlled adjustment during operation.
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 solution allows for precise control of the gap and alignment, enhancing the consistency and quality of the welding process by reducing unnecessary degrees of freedom, thereby improving the physical characteristics of the welded product.
Implementation Method 1
The converter (also referred to as a 'transducer') receives the AC signal and responds thereto by compressing and expanding at a frequency equal to that of the AC signal
Implementation Method 2
The horn vibrates, typically at 20,000 Hz to 40,000 Hz, transferring energy, typically in the form of frictional heat, under pressure, to the parts
Implementation Method 3
A mounting system that restricts the horn and anvil to specific degrees of freedom, allowing only rotational motion about their respective axes and translational motion perpendicular to these axes
Implementation Method 4
with additional adjustments using threaded fasteners to control the gap and align the horn's longitudinal axis parallel to the anvil's
Data Source
AI summary
An ultrasonic rotary welding apparatus and methods of using the same are disclosed. The ultrasonic welding device includes an ultrasonic horn and an anvil. The ultrasonic horn is constrained by a mounting system. The mounting system permits the horn to exhibit two degrees of freedom. The first degree of freedom permits translational motion in a direct perpendicular to the longitudinal axis of the horn. The second degree of freedom permits rotation about an axis perpendicular to both the longitudinal axis of the horn and the direction of translational motion.