Ultrasonic Trigger Device for Sealing Elevation Control
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Solution Overview
Problem
Current ultrasonic processing systems face challenges in maintaining a constant vibration amplitude during high-speed material processing, particularly due to abrupt load changes caused by structures on the sonotrode and counter tool, leading to fluctuations and post-oscillations that disrupt control processes.
Innovation Solution
A trigger device is implemented to determine the position of elevations on the counter tool, allowing or preventing the linkage of process variables with manipulated variables based on contact status, using a position sensor to switch between measured force and a reference value to minimize disruptive effects on control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sonotrode is equipped with elevations to create sealing surfaces, then sealing capability is improved, but the force exerted by the sonotrode on the counter tool increases abruptly, leading to coupling of the oscillating system and damping of vibration
Solution Approach 1:
The trigger device determines the position of the elevation in advance and allows or prevents linking of the process variable with the manipulated variable before the elevation contacts the material. This preliminary positioning enables the control system to prepare for upcoming load changes, switching to reference value control before contact occurs to avoid disruptions from post-contact measurements.
Solution Approach 2:
The trigger device acts as an intermediary between the position detection system and the control system. It processes the position information of the elevation and conditionally activates the linkage between process variable and manipulated variable, mediating the interaction between the mechanical processing system and the control system to prevent harmful coupling effects.
2Reliability
If the control system reacts to load changes, then vibration amplitude can be maintained, but at higher processing speeds the bump is in contact with material for very short time, so control system reacts too late
Solution Approach 1:
The trigger device determines the position of the elevation in advance and allows or prevents linking of the process variable with the manipulated variable before the elevation contacts the material. This preliminary positioning enables the control system to prepare for upcoming load changes, switching to reference value control before contact occurs to avoid disruptions from post-contact measurements.
Solution Approach 2:
The control system alternates between two operational modes: linkage mode (when elevation is not in contact) and reference value mode (when elevation is in contact). This periodic switching between control strategies synchronizes with the cyclic contact events, allowing the system to adapt its control approach based on the contact state.
3Measurement precision
If force sensor is installed to measure force for control, then process variable can be determined, but post-oscillations occur after elevation disengages, causing force sensor measurements to oscillate and disrupt control process
Solution Approach 1:
The trigger device extracts and removes the harmful post-oscillation measurements from the control process. By detecting when the elevation has disengaged from the material, the trigger device prevents the oscillating force sensor signals from being linked to the manipulated variable, effectively separating the useful contact-phase measurements from the harmful post-contact oscillations.
Solution Approach 2:
The trigger device acts as an intermediary between the position detection system and the control system. It processes the position information of the elevation and conditionally activates the linkage between process variable and manipulated variable, mediating the interaction between the mechanical processing system and the control system to prevent harmful coupling effects.
4Productivity
If processing speed is increased to higher speeds, then productivity is improved, but the bump is only in contact with material for very short time, making it difficult to keep vibration amplitude constant
Solution Approach 1:
The trigger device determines the position of the elevation in advance and allows or prevents linking of the process variable with the manipulated variable before the elevation contacts the material. This preliminary positioning enables the control system to prepare for upcoming load changes, switching to reference value control before contact occurs to avoid disruptions from post-contact measurements.
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 faster and more precise control of the ultrasonic generator, reducing amplitude fluctuations and maintaining consistent processing conditions even at higher speeds by only applying corrective measures during actual material contact.
Implementation Method 1
The ultrasonic generator generates an electrical AC voltage, which is converted with the help of the converter into an acoustic ultrasonic vibration, the frequency of which is adapted to the sonotrode in such a way that it is set into resonance vibration.
Implementation Method 2
The ultrasonic generator generates an electrical AC voltage, which is converted with the help of the converter into an acoustic ultrasonic vibration, the frequency of which is adapted to the sonotrode in such a way that it is set into resonance vibration.
Implementation Method 3
The trigger device has a sensor for determining the position of the elevation.
Data Source
Figure 1~2
AI summary
The present invention relates to a device for the ultrasonic processing of materials, which has an ultrasonic processing system, which comprises: an ultrasound generator, a converter (12), a sonotrode (16), and a counter tool (18); wherein the sonotrode (16) and/or the counter tool (18) has a substantially cylindrical sealing surface having at least one elevation (45) and can be rotated such that, during the processing, the elevation (45) rotates about the axis of rotation and comes in contact with the material web (20) during a sealing time, wherein a control apparatus (24) is provided for the ultrasound generator, to which control apparatus a feedback variable from the ultrasound processing system is fed and which control apparatus determines a manipulated variable therefrom and feeds said manipulated variable to the ultrasound generator, wherein a process variable from the processing process is determined and is linked to the manipulated variable determined by the control apparatus (24) before the feeding to the ultrasound generator. In order to provide an improved device for the ultrasonic processing of materials having an ultrasonic processing system, a trigger apparatus (44) is provided, which determines the position of the elevation (45) and is designed to permit or prevent the linking of the process variable to the manipulated variable in accordance with the position determination.