Intermittent Ultrasonic Web Processing with Amplitude Modulation
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Solution Overview
Problem
Existing intermittent ultrasonic processing methods face challenges with material guidance at high web velocities and require frequent machine downtime due to cam control changes and tool compatibility issues with rotating tools.
Innovation Solution
The method involves varying ultrasonic oscillation amplitudes between processing and movement intervals, with amplitude A for processing and amplitude B for movement, where amplitude B is reduced but not zero, allowing continuous material flow without processing, and using rotary tools with constant force adjustments to maintain optimal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sonotrode is moved back and forth mechanically to interrupt ultrasonic processing, then intermittent processing is achieved, but material guidance problems occur at high web velocities and machine speed is limited
Solution Approach 1:
The patent replaces the mechanical cam control system with an electronic control system that modulates the ultrasonic oscillation amplitude. Instead of physically moving the sonotrode back and forth using mechanical components, the system uses electronic signals to vary the oscillation amplitude between a first amplitude (processing mode) and a second amplitude (movement mode), eliminating mechanical complexity and enabling high-speed operation without material guidance problems
Solution Approach 2:
The patent changes the operational parameter of the sonotrode from fixed mechanical position to variable ultrasonic oscillation amplitude. By controlling the amplitude parameter electronically rather than through mechanical displacement, the system achieves intermittent processing while maintaining stable material guidance at high web velocities
2Adaptability or versatility
If cam control is used for intermittent processing, then processing cycles are controlled, but machine downtime increases due to cam control exchange when changes are needed
Solution Approach 1:
The patent replaces the mechanical cam control system with an electronic control system that can be reprogrammed through software. This substitution allows processing cycle changes to be made by updating electronic control parameters rather than physically exchanging cam controls, eliminating machine downtime associated with mechanical component changes and significantly improving adaptability
Solution Approach 2:
The electronic control system serves multiple functions: it controls the ultrasonic oscillation amplitude, manages the processing intervals, and can be reprogrammed for different processing cycles. This multi-functionality replaces the need for multiple specialized mechanical cam controls, allowing a single system to handle various processing requirements without downtime
3Productivity
If rotating tools with chambers are used for intermittent processing, then processing is interrupted when material passes over chambers, but tool compatibility issues arise and tools must be exchanged for different chamber dimensions
Solution Approach 1:
The patent replaces the mechanical rotating tool system with chambers with an electronic control system that modulates ultrasonic oscillation amplitude. This eliminates the need for physical chambers and rotating mechanisms, allowing intermittent processing to be achieved through electronic timing and amplitude control, thereby improving tool compatibility and eliminating the need for tool exchanges
Solution Approach 2:
Instead of changing physical tool geometry (chamber dimensions) to achieve different processing intervals, the patent changes the temporal parameters of ultrasonic oscillation amplitude. By controlling when the amplitude switches between first and second values, the system achieves variable processing intervals without any physical tool changes, greatly enhancing versatility
4Use of energy by moving object
If the sonotrode is shut off completely during movement intervals, then energy is saved, but the sonotrode takes time to reach steady state again, reducing effectiveness at high web velocities
Solution Approach 1:
Instead of completely shutting off the sonotrode during movement intervals, the patent applies a reduced ultrasonic oscillation amplitude (second amplitude) that is less than the processing amplitude (first amplitude) but greater than zero. This partial action maintains the sonotrode in a warm, active state that requires minimal time to reach full processing capability again, while still saving energy compared to continuous full-power operation
Solution Approach 2:
The patent implements periodic switching between two ultrasonic oscillation amplitudes rather than complete on/off cycling. This periodic modulation between first and second amplitudes creates a more gradual transition that reduces thermal shock and allows faster stabilization when switching back to processing mode, improving both energy efficiency and processing quality recovery
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 enhances processing efficiency at high velocities, reduces machine downtime, and allows for precise control of material processing by maintaining continuous material flow and minimizing wear on tools.
Implementation Method 1
In a processing interval the sonotrode is stimulated by an ultrasonic oscillation with an oscillation amplitude A
Data Source
AI summary
The present invention relates to a method for intermittent ultrasonic processing of a length of material, wherein a length of material is moved through between a sonotrode and a counter-tool and the length of material is processed intermittently. In order to specify a method for intermittent ultrasonic processing of a length of material by which the disadvantages of the prior art can be avoided or at least reduced, according to the invention it is suggested that in a processing interval the sonotrode is stimulated by an ultrasonic oscillation with an oscillation amplitude A and in a movement interval the sonotrode is stimulated with an oscillation amplitude B, wherein B<A and during the processing interval and during the movement interval the length of material touches both the sonotrode and also the counter-tool.