Closed-loop Ultrasonic Horn Leveling for Disposable Garment Bonding
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Solution Overview
Problem
Manual adjustment of the gap and leveling between an ultrasonic horn and a patterned anvil in ultrasonic bonding systems for disposable garments is inefficient, leading to varied bonding conditions and operational interruptions, as it requires manual intervention and cannot be performed continuously during machine operation.
Innovation Solution
A closed-loop control system with an actuator is implemented to monitor operational parameters and adjust the orientation of the ultrasonic horn relative to the anvil, ensuring parallel alignment and maintaining a consistent gap, allowing for automated and continuous adjustments during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of gap and leveling is performed, then the ultrasonic horn placement can be adjusted, but the bonding conditions become non-uniform and the machine must be stopped
Solution Approach 1:
The system employs sensors to continuously monitor the gap distance between the ultrasonic horn and anvil, feeding this information back to a control system that automatically adjusts the horn position to maintain uniform bonding conditions throughout the cross-machine direction
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses electronic sensors and actuators to maintain precise gap control, eliminating the need for operator intervention and ensuring consistent bonding parameters
2Ease of operation
If manual adjustment of gap and leveling is performed, then the ultrasonic horn placement can be adjusted, but operational interruptions occur
Solution Approach 1:
The system performs self-adjustment of the ultrasonic horn position through automated sensors and actuators, enabling the machine to correct gap variations without requiring operator intervention or production stoppage
Solution Approach 2:
The automated gap control system operates continuously during machine running, ensuring uninterrupted production while maintaining optimal bonding conditions through real-time adjustment of the ultrasonic horn position
3Device complexity
If non-ideal gap distance is maintained, then the machine structure is simpler, but blow-out phenomenon occurs
Solution Approach 1:
Sensors continuously measure the gap distance and provide feedback to the control system, which automatically adjusts the ultrasonic horn position to prevent blow-out by maintaining the optimal gap distance throughout the cross-machine direction
Solution Approach 2:
The system transitions from static manual gap setting to dynamic automated adjustment, where the gap distance is continuously monitored and adjusted in real-time to prevent blow-out phenomenon while accommodating variations in the bonding process
4Device complexity
If non-ideal gap distance is maintained, then the machine structure is simpler, but bonding fails to occur
Solution Approach 1:
The control system uses sensors to monitor gap distance and automatically adjusts the ultrasonic horn position to maintain the optimal gap for reliable bonding, preventing bonding failures caused by excessive or insufficient gap distance
Solution Approach 2:
The patent replaces simple but unreliable manual gap setting with an automated control system that ensures consistent optimal gap distance, thereby guaranteeing reliable bonding across all bond lines without requiring complex manual intervention
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 enables consistent bonding conditions across the machine direction, prevents 'blow-out' phenomena, and allows the machine to operate continuously, improving the quality and efficiency of ultrasonic bonding in disposable garment production.
Implementation Method 1
The ultrasonic horn contains an ultrasonic emitting assembly. Layers of non-woven fabric, which may or may not contain additional garment components, are passed between the patterned anvil and the ultrasonic horn. The layers contact the raised pattern on the patterned anvil. While in contact with the raised pattern, the layers pass through an ultrasonic emission created by the ultrasonic horn. The ultrasonic emission increases the vibrations of the particles in the non-woven garment, thus increasing the temperature of the particles in the non-woven garment.
Implementation Method 2
Ultrasonic energy is concentrated at specific bond points where frictional heat bonds non-woven fabric of the garment layers.
Data Source
AI summary
An apparatus and method for leveling a bonding device and anvil in an assembly via a closed-loop control system is provided. The assembly includes an anvil, a bonding device positioned adjacent the anvil and configured to interact with the anvil to form the bonds on the web, and an actuator that enables adjustment of an orientation between the bonding device and the anvil. The assembly also includes a closed-loop control system configured to control operation of the actuator, with the closed-loop control system configured to monitor an operational parameter of the assembly indicative of interaction of the bonding device with the anvil, determine whether the bonding device is parallel or substantially parallel with the anvil based on the operational parameter, and when the bonding device is not parallel or substantially parallel with the anvil, cause the actuator to adjust the orientation between the bonding device and the anvil.