Ultrasonic Additive Welding Head With Pressure-Temperature Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing systems, such as those using fused filament fabrication, lack the capability to simultaneously control pressure and temperature, which is necessary for efficient welding and surface quality improvement.
Innovation Solution
An ultrasonic manufacturing system that employs a robotic arm with a coupling unit and a manufacturing head equipped with an ultrasonic welder, mass control unit, and sensors to apply pressure and temperature simultaneously, allowing for continuous and controlled welding of materials like CFRP tape and other composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional FFF additive manufacturing is used, then material deposition is achieved, but pressure control is lost and surface quality deteriorates
Solution Approach 1:
The patent merges ultrasonic welding technology with additive manufacturing by integrating an ultrasonic welding head into the extruder assembly. This combination allows simultaneous material deposition and welding with controlled pressure and temperature, improving surface quality without requiring separate welding equipment.
Solution Approach 2:
The ultrasonic welding head acts as an intermediary between the extruder and the build plate, providing controlled pressure and temperature to the deposited material. This intermediary component enables precise pressure control that conventional FFF systems lack, thereby improving surface quality.
2Strength
If higher pressure is applied during welding, then bonding strength improves, but surface quality deteriorates and energy consumption increases
Solution Approach 1:
The ultrasonic welding system changes the parameters of welding by using high-frequency vibrations (typically 20-40 kHz) instead of static pressure. This parameter change allows achieving strong bonds with lower overall pressure and energy consumption, as the vibrational energy directly facilitates molecular diffusion and bonding.
Solution Approach 2:
The patent applies mechanical vibration through the ultrasonic welding head to the deposited material. The high-frequency vibrations generate heat through internal friction and facilitate material bonding, reducing the need for high static pressure and thereby lowering energy consumption while maintaining bonding strength.
3Productivity
If continuous manufacturing is implemented, then productivity increases, but control over welding parameters becomes difficult
Solution Approach 1:
The system incorporates feedback control through sensors that monitor welding parameters such as temperature, pressure, and vibration amplitude in real-time. This feedback enables continuous adjustment of parameters during manufacturing, maintaining precision even at high speeds and enabling continuous operation without sacrificing control.
Solution Approach 2:
The ultrasonic welding system is designed with dynamic capabilities, allowing real-time adjustment of welding parameters during continuous operation. The system can adapt welding speed, amplitude, and pressure dynamically, enabling continuous manufacturing while maintaining precise control over welding quality.
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 system enhances surface quality, reduces the pressure required for welding, and enables the production of complex pieces by depositing and joining materials layer-by-layer, achieving high bonding strength and low porosity in the welded joints.
Implementation Method 1
an ultrasonic welder... comprising an ultrasonic transducer, a booster and an ultrasonic horn
Implementation Method 2
apply temperature in a controlled manner... applying simultaneously pressure and temperature
Implementation Method 3
a mass control unit configured to add and remove masses from the manufacturing head automatically
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Additive ultrasonic manufacturing system for additive manufacturing applying simultaneously pressure and temperature, comprising: a robot or a robotic arm; a coupling unit, attached to the robot or robotic arm and comprising a sliding channel; a manufacturing head connected to the coupling unit and comprising at least one ultrasonic welder, and a mass control unit, configured to add and remove masses from the head automatically; and an additive ultrasonic manufacturing method comprising the steps of determining a first amplitude and a first power for the ultrasonic welder; determining a first mass for adding to the manufacturing head; determining a first velocity for the manufacturing head; activating the ultrasonic welder and the robot or robotic arm; measuring a temperature and a pressure applied on the manufacturing surface; modifying the first amplitude, the first power and the first mass determined to achieve a welding temperature and pressure for the material to be welded.