Ultrasonic Welding Stop Element for Variable Joint Positioning
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Solution Overview
Problem
Conventional ultrasonic welding devices require complex assembly and manual intervention for precise positioning of components, leading to inefficiencies and inconsistent weld quality, especially when transitioning between end and through-joint configurations.
Innovation Solution
An ultrasonic welding device with a movable stop element and drive unit that automatically adjusts the receiving space to accommodate different welding configurations, allowing for precise alignment and easy operation, including integrated sensors and a human-machine interface for automated control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed stop element is used to limit the stroke of the ultrasonic horn, then the stroke is precisely controlled, but the device cannot adapt to different welding depths and requires multiple stop elements for different applications
Solution Approach 1:
The stop element is made movable along the guide rail instead of being fixed, allowing it to be repositioned for different welding depths. This dynamic positioning capability enables a single stop element to replace multiple fixed stop elements, reducing device complexity while improving adaptability.
Solution Approach 2:
The movable stop element serves multiple functions: it can be positioned at different locations along the guide rail to accommodate various welding depths, and it can be removed entirely if unlimited stroke is required. This multi-functionality eliminates the need for multiple specialized stop elements.
2Reliability
If the ultrasonic horn is allowed to move freely without a stop element, then the device is simpler to operate, but the stroke cannot be controlled leading to potential damage to the ultrasonic generator
Solution Approach 1:
The movable stop element provides controlled restriction rather than fixed limitation. It can be positioned to allow adequate stroke for normal operation while preventing excessive movement that could damage the generator. The stop element can also be removed when maximum stroke is needed, providing both protection and flexibility.
Solution Approach 2:
The guide rail acts as an intermediary between the ultrasonic horn and the stop element, providing guided movement while the stop element provides controlled limitation. This intermediary system allows the horn to move freely within safe limits while preventing dangerous excursions.
3Adaptability or versatility
If multiple fixed stop elements are installed at different positions, then different welding depths can be achieved, but the device complexity increases and requires changing stop elements for different applications
Solution Approach 1:
Instead of having multiple fixed stop elements at predetermined positions, a single stop element is made movable along the guide rail. This allows the stop element to be repositioned to any location as needed, providing the same adaptability as multiple fixed elements but with simpler configuration and manufacturing.
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 positioning of components, reducing downtime and ensuring consistent weld quality across various configurations, such as end and through-joints, by automating the positioning process.
Implementation Method 1
an ultrasonic horn (30) arranged to vibrate in an ultrasonic frequency range in a direction towards the other plastic part (20, 40) when the ultrasonic device (10, 50) is activated
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to an ultrasonic welding device (1) which comprises a sonotrode (3), an anvil (5), a touching element (7), a lateral slide (9), a first stop element (11), a drive device (29) and a receiving space (13) in which joining partners (15) are to be received. The receiving space is delimited on a first side by a surface (21) of the sonotrode and on a second side, which is opposite the first side, by a surface (23) of the anvil. The receiving space is also delimited on a third side by a surface (25) of the touching element and on a fourth side, which is opposite the third side, by a surface (27) of the lateral slide. The first stop element is movable between a retracted position and an extended position. In the retracted position, the first stop element delimits the receiving space on a fifth side which extends transversely to the first to fourth sides, and in the extended position, the first stop element leaves the receiving space open on the fifth side. The drive device is designed to move the first stop element actively between the retracted position and the extended position. (Figure 1)