Ultrasonic Press Welding With Force-Based Weld Phase Control
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Solution Overview
Problem
Traditional ultrasonic welding methods fail to accurately weld physically variant components due to inconsistent energy directors and material variations, leading to inefficiencies and errors in the welding process.
Innovation Solution
Implementing a method that monitors and determines the weld force or force rate of change to end the weld phase, allowing for consistent welding of components with varying shapes and sizes by using sensors to ensure a predetermined level is reached, eliminating the need for frequent recalibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional ultrasonic welding methods use fixed time, position, or distance parameters to end the weld phase, then the welding process is simple to control, but the welding accuracy deteriorates when components have physical variations in energy directors
Solution Approach 1:
The patent employs real-time feedback from sensors (load cells, force sensors) that continuously monitor weld force, force rate of change, or energy consumption during the ultrasonic welding process. This feedback is fed back to the control system, which dynamically adjusts the welding parameters to maintain optimal welding conditions for physically variant components, thereby improving welding accuracy without requiring overly complex manual intervention
Solution Approach 2:
The patent replaces traditional mechanical control methods (fixed timers, position-based control) with sensor-based detection systems that use electrical and electronic components to monitor welding parameters. This substitution enables more precise control of the welding process by using electronic sensing and control circuits rather than purely mechanical timing and positioning mechanisms
2Manufacturing precision
If the ultrasonic press is recalibrated frequently to accommodate physical variations in workpieces, then welding accuracy can be maintained, but productivity decreases due to frequent interruptions
Solution Approach 1:
The patent implements a self-adjusting welding system that automatically adapts to physical variations in workpieces through real-time sensor feedback. The control system continuously monitors welding parameters and automatically adjusts process variables without requiring operator intervention or recalibration, enabling the system to serve itself by maintaining optimal welding conditions across different workpiece variations, thereby preserving productivity while ensuring welding accuracy
Solution Approach 2:
The patent transitions from static, fixed welding parameters to dynamic, adaptive control where welding parameters are continuously adjusted based on real-time sensor data. The system dynamically responds to variations in workpiece geometry, material properties, and welding conditions, allowing the welding process to adapt automatically without manual recalibration, thus maintaining both accuracy and productivity
3Reliability
If the weld phase duration is extended to accommodate larger energy directors, then all workpieces can be adequately welded, but energy consumption and cycle time increase for smaller workpieces
Solution Approach 1:
The patent uses real-time feedback from force sensors and energy monitoring systems to detect when the welding objective has been achieved for each specific workpiece. The control system continuously monitors welding parameters and automatically terminates the weld phase when the predetermined welding objective is met, preventing unnecessary continuation of the welding process for smaller energy directors, thereby reducing energy consumption while maintaining consistent weld quality across all workpiece sizes
Solution Approach 2:
The patent dynamically changes welding parameters (duration, power level) based on real-time detection of workpiece characteristics and welding progress. By adjusting the weld phase duration and energy input according to the actual needs of each workpiece rather than using fixed parameters, the system optimizes energy consumption while ensuring adequate welding for all workpiece variations
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 approach ensures accurate and efficient welding of components with different physical characteristics, achieving higher accuracy and lower error rates compared to conventional methods.
Implementation Method 1
an ultrasonic welding stack (10) that can be moved to press against a first workpiece (W1) in a pair of workpieces to cause the first workpiece to contact a second workpiece (W2)
Implementation Method 2
outputting energy from the ultrasonic welding stack to the first workpiece
Implementation Method 3
a sensor configured to detect a weld force or a force rate of change
Data Source
AI summary
The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.