Ultrasonic Weld Joint Position Detection Using Conductive Stops
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Solution Overview
Problem
Ultrasonic welding devices face challenges in ensuring accurate positioning of joining partners, leading to inconsistent quality of welds due to manual alignment requirements, which can result in variations in electrical conductivity and mechanical strength.
Innovation Solution
The ultrasonic welding device incorporates a detection system using electrically conductive electrodes to verify the correct positioning of joining partners by detecting an electrical closure between the first stop element and other components, ensuring alignment without the need for manual verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning with markings or stop elements is used, then the device structure remains simple, but the positioning precision and weld quality consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical positioning (markings, visual alignment) with an automated electrical detection system. Conductive elements are integrated into the sonotrode and anvil to automatically detect when joining partners are correctly positioned based on electrical conductivity changes, eliminating the need for manual verification while maintaining simple device structure.
Solution Approach 2:
The detection system uses the joining partners themselves as part of the detection circuit. The conductive elements on the sonotrode and anvil detect positioning through the electrical properties of the joining partners, allowing the system to self-verify positioning without external tools or complex mechanisms.
2Reliability
If manual positioning by operator is used, then the device complexity remains low, but the reliability of weld quality deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the electrical detection system continuously monitors the positioning of joining partners. When the conductive elements detect correct positioning through electrical conductivity changes, the system provides feedback to confirm proper alignment, ensuring consistent weld quality while keeping the device structure relatively simple.
3Manufacturing precision
If complex stop elements are installed for positioning, then the positioning precision improves, but the ease of operation and device setup deteriorates
Solution Approach 1:
The patent replaces complex mechanical stop elements with an electrical detection system integrated into the sonotrode and anvil. This eliminates the need for manual installation and removal of stop elements, while maintaining automated positioning detection through electrical conductivity changes, thereby improving ease of operation without sacrificing positioning precision.
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 enhances the operability and consistency of weld quality by automatically detecting correct positioning, reducing the likelihood of defective welds and ensuring reproducible alignment of joining partners.
Implementation Method 1
The first stop element is electrically conductive on its surface directed toward the receiving chamber in order to form a first electrode. At least one of the bordering components defining the receiving chamber, including the sonotrode, the anvil, the touching element and the lateral slide, is electrically conductive on its surface directed in each case toward the receiving chamber in order to form a second electrode.
Implementation Method 2
In this case, the vibrations may be generated with the aid of a sonotrode in which ultrasonic vibrations with frequencies of typically 20 kHz to 50 kHz are generated and transmitted to at least one of the joining partners.
Implementation Method 3
Ultrasonic welding was developed to produce substance-to-substance bonds between two electrically conductive components, providing them with high strength and good electrical conductivity. It is a special form of friction welding in which components to be welded, also referred to as joining partners or weld material, are brought into surface contact with each other and moved against each other under low pressure and high-frequency mechanical vibrations.
Data Source
AI summary
An ultrasonic welding device includes a sonotrode, an anvil, a touching element, a lateral slide, a stop element and a receiving chamber in which joining partners are received and which is defined by bordering components of the ultrasonic welding device. The receiving chamber is defined on a first side by the sonotrode and on a second side by the anvil. The receiving chamber is further defined on a third side by the touching element and on a fourth side by the lateral slide. The receiving chamber is further defined on a fifth side, extending transverse to the first to fourth sides, by the stop element. The first stop element is electrically conductive on its surface directed toward the receiving chamber in order to form a first electrode.