Ultrasonic Welding Head Assembly for Faster Battery Tab Positioning
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Solution Overview
Problem
Existing ultrasonic welding devices have low welding efficiency due to the need for three-axis movements to adjust the welding position, which is time-consuming, and the independent operation of the protective pressure plate, which reduces efficiency.
Innovation Solution
A welding device with a frame, welding assembly, fastening bracket, protective pressure plate, first drive mechanism, and second drive mechanism, where the second welding head and protective pressure plate are connected via a fastening bracket, allowing simultaneous movement and compression for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If three-axis movements are used to adjust the welding position, then the welding device can reach the welding point, but the welding efficiency is reduced due to time-consuming adjustments
Solution Approach 1:
The patent combines the protective pressure plate and the second welding head into a single movable assembly connected via a fastening bracket. This merging allows both components to move together along the X and Y axes through a single drive mechanism, eliminating the need for separate three-axis adjustments and significantly improving welding efficiency
2Reliability
If the protective pressure plate operates independently, then it can press the battery cell, but the welding efficiency is reduced due to separate positioning requirements
Solution Approach 1:
The protective pressure plate is integrated with the second welding head through the fastening bracket, creating a unified movable assembly. This ensures that both the pressing function and welding function are performed simultaneously by the same actuated system, eliminating independent positioning requirements and improving overall welding efficiency
3Device complexity
If the second welding head is fixed on the frame, then the structure is simple, but the welding position cannot be adjusted efficiently
Solution Approach 1:
The patent transforms the fixed second welding head into a dynamic component that can move along with the fastening bracket. The fastening bracket serves as a movable mounting structure that allows the second welding head to be repositioned efficiently while maintaining structural simplicity through the unified movement mechanism
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 solution enables faster and more efficient welding by allowing the second welding head and protective pressure plate to move synchronously, reducing the time required for positioning and improving overall welding efficiency.
Implementation Method 1
the welding assembly further includes an ultrasonic generator, the second welding head is connected to the ultrasonic generator
Implementation Method 2
the first drive mechanism includes a servo motor, a screw rod, and a screw nut, the servo motor is drivingly connected to the screw rod, the screw nut is provided on the screw rod and drivingly connected to the screw rod
Data Source
AI summary
A welding device may include a frame, a welding assembly, a fastening bracket, a protective pressure plate, a first drive mechanism, and a second drive mechanism; the welding assembly may include a first welding head and a second welding head that are arranged opposite each other, and the first welding head may be fastened on the frame; the fastening bracket may be movably provided on the frame, and the second welding head may be fastened on the fastening bracket; the protective pressure plate may be fastened on the fastening bracket or the second welding head; and the first drive mechanism may be drivingly connected to the fastening bracket and configured to drive the fastening bracket so that the second welding head may reach a position of a welding point and the protective pressure plate may press against a to-be-welded member.