Ultrasonic Weld Head Z-Axis Control for Precise Bond Force
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Solution Overview
Problem
Existing ultrasonic welding technologies face limitations in cost, operational efficiency, flexibility, and portability, failing to meet market demands for efficient volume production of interconnections between materials.
Innovation Solution
The ultrasonic welding system incorporates a z-axis motion system with a z-axis forcer and overtravel mechanism, allowing precise control of bond forces through a combination of linear motor-driven and pneumatic systems, enabling efficient welding of conductive terminals to workpieces with adjustable force calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing ultrasonic welding technology is used, then welding capability is provided, but cost, operational efficiency, flexibility, and portability fail to meet market demands
Solution Approach 1:
The welding system is divided into modular components: a weld head assembly containing the ultrasonic converter and sonotrode, a z-axis motion system with forcer and overtravel mechanism, and a support structure. This segmentation allows each module to be optimized independently while maintaining overall system efficiency and reducing complexity through standardized interfaces.
Solution Approach 2:
The weld head assembly is designed as a universal component that can be applied to various welding applications by changing the sonotrode geometry and welding parameters. The z-axis motion system with overtravel mechanism provides a standardized interface for different workpiece types, enhancing flexibility and adaptability across multiple manufacturing scenarios.
2Productivity
If high bond forces are applied for efficient welding, then welding speed and quality improve, but control precision and system flexibility may be compromised
Solution Approach 1:
The z-axis motion system employs dynamic control through a programmable forcer that can adjust bonding force in real-time during the welding cycle. The system transitions from static force application to dynamic force modulation, allowing high bonding forces during the welding phase while maintaining precise control through feedback mechanisms and programmable sequences.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor welding parameters including bonding force, ultrasonic power, and weld head position. This feedback enables real-time adjustments to maintain precise control over bond forces even at high welding speeds, ensuring consistent weld quality through closed-loop control.
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 configuration achieves high bond forces with precise control, enhancing operational efficiency and flexibility, suitable for volume production and various applications, including power modules.
Implementation Method 1
Ultrasonic welding may use an ultrasonic converter (e.g., carrying a sonotrode) for converting electrical energy into mechanical movement/scrub (e.g., linear movement/scrub, torsional movement/scrub, etc.)
Implementation Method 2
The z-axis motion system includes (i) a z-axis forcer for moving the weld head assembly along a z-axis of the ultrasonic welding system
Implementation Method 3
allowing precise control of bond forces through a combination of linear motor-driven and pneumatic systems
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The ultrasonic welding system also includes a z-axis motion system carrying the weld head assembly. The z-axis motion system includes (i) a z-axis forcer for moving the weld head assembly along a z-axis of the ultrasonic welding system, and (ii) a z-axis overtravel mechanism disposed between the z-axis forcer and the weld head assembly.