Ultrasonic Welding Anvil Motion for Stable Weld Alignment
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Solution Overview
Problem
Ultrasonic welding apparatuses experience misalignment of welding marks and unstable weld strength due to anvil misalignment during outbound and inbound movements, leading to diminished appearance and potential horn deterioration from shocks and excessive sonic output.
Innovation Solution
The apparatus and method involve controlling ultrasonic energy application to the workpiece on one path only, using a displacement mechanism to guide the anvil away from the horn at stroke ends and applying energy only in a non-driven state in overrun regions, preventing direct metal-on-metal contact and reducing sonic output thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the anvil reciprocates between outbound and inbound movements to perform welding, then welding productivity is improved, but misalignment of welding marks occurs and weld strength becomes unstable
Solution Approach 1:
The patent applies periodic action by controlling the ultrasonic generator to activate the horn only during the inbound movement of the anvil, while keeping it inactive during the outbound movement. This periodic activation pattern ensures welding occurs at consistent positions during each cycle, eliminating misalignment issues while maintaining continuous reciprocating motion for high productivity
2Manufacturing precision
If the anvil approaches the horn closely to weld the workpiece, then welding quality is improved, but wear and deterioration of the anvil and horn increase
Solution Approach 1:
The patent implements dynamic control of the anvil-horn distance by using a displacement mechanism that adjusts the anvil position based on the operational phase. During welding (inbound movement), the anvil approaches the horn to ensure quality welds. During non-welding phases (outbound movement), the displacement mechanism moves the anvil away from the horn, reducing contact and wear, thereby extending component service life
3Manufacturing precision
If the anvil impacts the horn from a first level to a second level, then the anvil reaches the welding position, but shocks are produced in the horn causing errors and deterioration
Solution Approach 1:
The patent applies beforehand cushioning by controlling the ultrasonic generator to deactivate the horn before the anvil impacts it during level transition. The displacement mechanism is timed to move the anvil away from the horn's path just before impact occurs, cushioning the blow and preventing shock-induced errors and deterioration while still allowing the anvil to reach the correct welding position
4Area of stationary object
If ultrasonic energy is applied continuously during both outbound and inbound movements, then welding coverage is improved, but misalignment occurs and appearance is diminished
Solution Approach 1:
The patent applies periodic action by controlling the ultrasonic generator to activate the horn only during the inbound movement of the anvil, while keeping it inactive during the outbound movement. This periodic activation pattern ensures welding occurs at consistent positions during each cycle, eliminating misalignment issues while maintaining continuous reciprocating motion for high productivity
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 stabilizes weld strength, prevents horn deterioration, and reduces errors by minimizing shocks and maintaining sonic output within safe limits, ensuring consistent and durable welds.
Implementation Method 1
an ultrasonic generator 16 configured to cause the horn 6 to vibrate to apply ultrasonic energy to the workpiece W sandwiched between the anvil 10 and the horn 6
Data Source
AI summary
Including a process of applying ultrasonic energy to a workpiece; a process of reciprocally moving an anvil between an overrun region and a non-welding region; a process of guiding the anvil such that the anvil reaches a first level away from a surface level of a horn so that the anvil does not abut against the horn at ends portions far from a welding region and moving the anvil to a second level where the anvil touches the horn in the welding region; and a process of performing control such that in the overrun region the anvil becomes displaced from the first level to the second level and the anvil abuts against the horn not via the workpiece in a non-driven state in which the horn is not being caused to generate ultrasonic energy.