Ultrasonic Welding Gap Adjustment via Deformable Stop
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Solution Overview
Problem
In ultrasonic welding, the gap between the horn and anvil narrows due to thermal expansion of the horn stack components, leading to inconsistent welding operations.
Innovation Solution
A system that maintains a constant gap by using a deformable stop and adjusting the force applied to the horn, coupled with a method to detect the resonant frequency of the horn stack to determine its length and adjust the gap accordingly, ensuring consistent energy transfer during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the horn stack operates during welding, then welding operations can be performed, but thermal expansion causes the gap between horn and anvil to narrow
Solution Approach 1:
The system transitions from a static gap configuration to a dynamic one by introducing a deformable stop that can adjust its position. The stop deforms elastically in response to thermal expansion of the horn stack, maintaining a constant gap between the horn and anvil despite temperature changes. This dynamic adjustment mechanism resolves the contradiction by allowing continuous operation while preserving gap precision.
Solution Approach 2:
The system changes the physical state of the stop from rigid to deformable, allowing it to undergo elastic deformation. By selecting a material with appropriate elastic properties, the stop can compensate for thermal expansion through controlled deformation, thereby maintaining the gap parameter constant even as temperature increases during welding operations.
2Device complexity
If a rigid stop is used to maintain gap, then结构简单 (structure is simple), but it cannot compensate for thermal expansion
Solution Approach 1:
The stop material is selected to have specific elastic properties that allow controlled deformation. This parameter change from rigid to elastomeric material enables the stop to undergo reversible deformation in response to thermal expansion, providing automatic compensation without complex control systems or multiple components.
Solution Approach 2:
The deformable stop provides self-compensating functionality by automatically deforming in response to thermal expansion forces. The system does not require external sensors, actuators, or control systems to maintain the gap - the elastic material inherently responds to temperature changes and adjusts the gap accordingly, simplifying the overall system while improving reliability.
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 maintains a uniform and reliable welding operation by keeping the gap between the horn and anvil constant, despite thermal expansion, thereby ensuring consistent energy transfer and quality of the weld.
Implementation Method 1
A deformable stop is positioned at a location, so that application of the urging force causes a member operatively connected to the horn to abut the deformable stop, and to deform the stop.
Implementation Method 2
During operation, one or more components of the horn stack, including the horn, itself, generally experience an elevation in temperature. Thus, the horn stack generally experiences thermal expansion.
Implementation Method 3
The horn vibrates, typically at 20,000 Hz to 40,000 Hz, transferring energy, typically in the form of frictional heat, under pressure, to the parts.
Implementation Method 4
The horn vibrates, typically at 20,000 Hz to 40,000 Hz, transferring energy, typically in the form of frictional heat, under pressure, to the parts.
Data Source
AI summary
A system and method for adjusting the gap between a horn and an anvil in an ultrasonic welding system includes the act of positioning a horn proximal to an anvil, so that a gap is established between the horn and the anvil. A force is applied to the horn, so as to urge the horn toward the anvil. A deformable stop is positioned at a location, such that application of the urging force causes a member operatively connected to the horn to abut the deformable stop, and to deform the stop. The urging force is iteratively adjusted during operation of the horn, so as to adjust the extent of the deformation of the deformable stop, and to maintain the gap between the horn and the anvil substantially constant.