Ultrasonic Welding Apparatus for Conductor Positioning
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Solution Overview
Problem
Existing ultrasonic welding devices for rod-shaped electrical conductors with insulating coverings face challenges in precise positioning due to cramped spatial conditions and small contact areas between conductors and stop elements, requiring skilled operator handling.
Innovation Solution
A positioning device is arranged outside the compression space with a transfer device that includes pivot arms and clamping devices, allowing conductors to be positioned and aligned outside the compression space, then transferred into the welding position using a combination of transfer and axial feed movements, eliminating the need for precise handling within the narrow space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the positioning device is integrated into the compression space, then the device structure is compact, but the positioning precision deteriorates due to cramped spatial conditions and small contact areas
Solution Approach 1:
The device is divided into two functional parts: a positioning device with stop elements arranged outside the compression space, and a transfer device that moves conductors from the positioning location to the compression space. This segmentation allows precise positioning to occur in a spacious area while maintaining overall device compactness.
Solution Approach 2:
The transfer device acts as an intermediary between the positioning device and the compression space. It receives conductors positioned by the positioning device and transfers them to the welding position, enabling precise positioning without requiring the positioning elements to be inside the cramped compression space.
2Device complexity
If the stop elements are positioned within the compression space, then the device structure is simplified, but the ease of operation deteriorates due to the need for skilled handling in narrow spaces
Solution Approach 1:
The positioning and welding functions are separated into different spatial locations. The positioning device with stop elements is located outside the compression space where there is ample room for operator manipulation, while the compression space remains dedicated to the welding operation.
Solution Approach 2:
The transfer device serves as an intermediary that bridges the positioning operation and the welding operation. It takes conductors positioned by the operator in the accessible area and delivers them to the compression space, eliminating the need for operators to work in the narrow compression space.
3Productivity
If the conductors are positioned directly in the compression space, then the transfer process is eliminated, but the reliability of positioning deteriorates due to the risk of misalignment from small contact areas
Solution Approach 1:
The positioning of conductors is performed in advance in a spacious area outside the compression space, where stop elements provide stable positioning with adequate contact areas. This preliminary positioning action ensures reliability before the conductors are transferred to the compression space for welding.
Solution Approach 2:
The transfer device acts as a reliable intermediary that preserves the positioning accuracy achieved in the preliminary stage. It transfers conductors without disturbing their aligned positions, ensuring that the reliable positioning is maintained throughout the transfer to the compression space.
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 simplifies and enhances the positioning of conductors, reducing the risk of misalignment and surface damage during ultrasonic welding, enabling precise and safe alignment of conductor ends without operator skill dependency.
Implementation Method 1
an ultrasonic welding device (10) for welding rod-shaped electrical conductors (17, 28, 29)
Data Source
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AI summary
The invention relates to an ultrasonic welding apparatus (10) for welding rod-like electric conductors (17, 28, 29) which are provided with an external insulating envelope and have bare regions (33) freed of the envelope, comprising a compression space arrangement (41) having a compression space for receiving bare regions to be connected together, and a positioning device (42) for positioning the bare regions (33) relative to one another, wherein the positioning device has two stop elements (46, 47) which each have a stop surface (48, 49) for axially positioning a bare region (33), such that, in order to form a welded joint between the bare regions (33), a covering with a covering length l is formed, wherein the positioning device (42) is arranged away from the compression space arrangement (41) and is provided with a transfer device (43) which has a receiving device (52) for the fixed reception of the conductors (17, 28, 29), positioned axially by means of the positioning device (42), outside the compression space (18), and the transfer device (43) serves to transfer the conductors (17, 28, 29), fixed in a receiving position in the receiving device (52), into the welding position in the compression space.