Ultrasonic Welding Horn Stroke Control for Accurate Pressing Force
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Solution Overview
Problem
Existing ultrasonic welding technologies lack the ability to accurately measure and adjust the pressing force of the horn, leading to inconsistent welding quality and potential wear of the horn and anvil due to variations in pressing force.
Innovation Solution
An ultrasonic welding apparatus equipped with a pressing force measuring anvil and a horn down stroke adjustment mechanism, utilizing sensors and controllers to ensure the pressing force is within a preset range, preventing welding failures and wear.
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 cause inaccurate measurements
Solution Approach 1:
The pressing force measurement function is extracted from the welding anvil and implemented separately on the measurement anvil. This separation allows accurate measurement of the horn's pressing force without the interference of ultrasonic vibrations that occur during actual welding, as the measurement and welding operations are performed on different anvils.
Solution Approach 2:
The pressing force measurement is performed in advance on the measurement anvil before actual welding begins. By measuring the pressing force preliminarily and adjusting the horn's down stroke accordingly, the system ensures accurate pressing force control without the complexity of measuring during ultrasonic vibration.
2Strength
If the horn pressing force is increased to prevent weak welding, then welding strength is improved, but horn and anvil wear out early
Solution Approach 1:
The system uses feedback from the pressing force measurement on the measurement anvil to adjust the horn's down stroke. By continuously monitoring and adjusting the pressing force to maintain it within the optimal range, the system prevents both weak welding (which would require excessive force) and excessive wear (caused by overly high force), thereby extending component life while ensuring weld quality.
Solution Approach 2:
The horn's down stroke is made adjustable based on measured pressing force conditions. This dynamic adjustment allows the system to optimize pressing force for each welding operation, preventing both insufficient welding strength and excessive wear on the horn and anvil.
3Adaptability or versatility
If the horn pressing force varies with different welding target members, then adaptability is improved, but welding quality consistency deteriorates
Solution Approach 1:
The system measures the actual pressing force on the measurement anvil for each welding target member and uses this feedback to adjust the horn's down stroke. This ensures that regardless of variations in welding target members, the pressing force is consistently maintained within the optimal range, achieving both adaptability and welding quality consistency.
Solution Approach 2:
The system changes the horn's down stroke parameter based on measured pressing force conditions for different welding target members. By adjusting this parameter dynamically, the system maintains consistent welding quality across different materials and configurations while adapting to their specific requirements.
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 control of the pressing force, ensuring consistent welding quality and extending the lifespan of the horn and anvil by maintaining optimal conditions during 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 apparatus includes: a pressing force measuring anvil including a pressing force measuring sensor; a horn which is installed to vertically move above the pressing force measuring anvil and presses the pressing force measuring anvil when moving downward; a horn down stroke adjustment part that adjusts a down stroke of the horn so that a pressing force of the horn is within a preset pressing force range; and a welding anvil on which welding target members to be welded by the horn are and supportable by the welding anvil and of which a position is changed to a position of the pressing force measuring anvil so that the welding anvil is positioned under the horn after the down stroke of the horn is adjusted to be within the preset pressing force range.