Ultrasonic Welding Force Feedback for Variant Workpieces
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Solution Overview
Problem
Existing ultrasonic welding methods fail to accurately weld physically variant workpieces due to inconsistent energy directors and material variations, leading to inefficiencies and errors from frequent recalibration.
Innovation Solution
Implementing sensors to monitor weld force or force rate of change, with time delays if necessary, to determine when a predetermined level is reached, ensuring consistent welding regardless of physical variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed-time or fixed-distance welding methods are used, then the welding process is simple to control, but welding quality becomes inconsistent when workpieces have physical variations
Solution Approach 1:
The patent implements real-time monitoring of weld force during the ultrasonic welding process. A force sensor continuously measures the force applied to the workpiece, and this feedback signal is used to dynamically adjust or terminate the welding cycle. This ensures that welding stops at the optimal moment when the weld is complete, regardless of variations in workpiece geometry or material properties, thereby maintaining consistent welding quality without requiring complex recalibration procedures.
2Manufacturing precision
If frequent recalibration is performed to accommodate physical variations, then welding accuracy is maintained, but productivity decreases
Solution Approach 1:
The welding system performs self-calibration by automatically adapting to each workpiece through real-time force monitoring. The force sensor detects the actual mechanical response of each workpiece during welding, and the control system automatically adjusts the welding parameters based on this information. This self-adjusting capability eliminates the need for manual recalibration between workpieces, maintaining high welding accuracy while preserving production efficiency.
3Reliability
If fixed welding parameters are used for all workpieces, then the welding process is efficient and fast, but welding reliability decreases for variant workpieces
Solution Approach 1:
The patent transforms the static, fixed-parameter welding process into a dynamic one by continuously monitoring weld force and adjusting the welding cycle in real-time. The welding process adapts its duration and intensity based on the actual mechanical response of each workpiece, allowing the system to maintain consistent welding quality across variant workpieces without significantly extending the overall welding cycle time.
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
Achieves consistent weld quality and reduces errors by adapting to physical variations in workpieces without recalibration, enhancing accuracy and efficiency.
Implementation Method 1
an ultrasonic welding stack that presses against a first workpiece in the pair of workpieces to cause the first workpiece to contact a second workpiece in the pair of workpieces
Implementation Method 2
outputting energy from the ultrasonic welding stack to the first workpiece
Data Source
AI summary
The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.