Ultrasonic Welding Force Calibration to Prevent Weak Welds and Wear
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Solution Overview
Problem
Existing ultrasonic welding technologies lack accurate measurement and adjustment of the pressing force of the horn, leading to inconsistent welding quality and premature wear of the horn and anvil.
Innovation Solution
An ultrasonic welding apparatus with a pressing force measuring anvil equipped with a sensor, a horn that adjusts its down stroke to maintain a preset pressing force, and a welding anvil that positions under the horn after stroke adjustment, ensuring consistent welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is installed on the anvil to measure pressing force, then measurement capability is improved, but ultrasonic vibrations interfere with accurate measurement
Solution Approach 1:
The anvil is divided into two separate components: a pressing force measuring anvil equipped with sensors for measurement, and a welding anvil for actual welding operations. This segmentation allows the measuring anvil to be removed before welding, eliminating vibration interference while maintaining measurement capability.
Solution Approach 2:
The pressing force is measured in advance using the pressing force measuring anvil before the actual welding process begins. This preliminary measurement allows adjustment of the horn's pressing force to within a preset range, ensuring optimal welding conditions without the interference of ultrasonic vibrations during measurement.
2Reliability
If the horn pressing force is not accurately controlled, then welding quality consistency deteriorates, but adding measurement and adjustment mechanisms increases device complexity
Solution Approach 1:
The system performs preliminary measurement of pressing force using the pressing force measuring anvil before welding, and adjusts the horn's down stroke in advance to ensure pressing force is within the preset range. This preliminary control ensures consistent welding quality without requiring complex real-time control systems during welding.
Solution Approach 2:
The pressing force measuring anvil acts as an intermediary device that facilitates accurate measurement and adjustment of pressing force. By using this intermediate measuring component, the system achieves reliable pressing force control while keeping the overall device structure relatively simple and modular.
3Strength
If the horn pressing force is too large, then welding strength is improved, but horn and anvil wear out prematurely
Solution Approach 1:
The pressing force is measured and adjusted in advance using the pressing force measuring anvil before welding begins. This allows the operator to set the horn's down stroke to achieve optimal pressing force within the preset range, ensuring sufficient welding strength while avoiding excessive force that would cause premature wear.
Solution Approach 2:
The pressing force measuring sensor provides feedback on the actual pressing force applied by the horn. This feedback mechanism allows for adjustment of the horn's down stroke to ensure pressing force remains within the optimal range, preventing both insufficient welding strength and excessive wear on the horn and anvil.
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
The apparatus enables precise measurement and adjustment of the horn's pressing force, preventing weak welding and anvil wear, thereby improving the consistency and reliability of the welding process.
Implementation Method 1
a pressing force measuring anvil, the pressing force measuring anvil including a pressing force measuring sensor
Implementation Method 2
A horn 10 which provides vibrations for ultrasonic welding is positioned above the anvil 20. The horn 10 moves downward to the tabs W1 and the lead W2, which are welding target members, and presses and vibrates the welding target members to ultrasonically weld the tabs and the lead.
Data Source
AI summary
An ultrasonic welding method including arranging a pressing force measuring anvil including a pressing force measuring sensor under a horn, moving the horn downward, pressing the pressing force measuring anvil, and measuring a pressing force of the horn using the pressing force measuring sensor, comparing the measured pressing force of the horn with a preset pressing force range and controlling a down stroke of the horn so that the pressing force of the horn is within the preset pressing force range, changing the pressing force measuring anvil with a welding anvil and positioning the welding anvil under the horn after the down stroke of the horn is adjusted, supporting welding target members on the welding anvil, and moving the horn by the adjusted down stroke and ultrasonically welding the welding target members on the welding anvil.