Ultrasonic Welding Control with Interval-Based Parameter Switching
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Solution Overview
Problem
Existing ultrasonic welding methods are not optimal for all applications due to variability in component geometries and structures, leading to inconsistent welding results, as the necessary welding period and force requirements can differ significantly between pairs of components due to factors like surface flatness and material tolerances, and the use of multiple forces is not always effective.
Innovation Solution
A method that divides the welding process into intervals where specific welding variables such as frequency, amplitude, force, power, and speed are kept constant until predetermined target variables like energy, time, or distance are reached, allowing for adaptable control of the welding process to ensure consistent results across varying materials and geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding process is prolonged to ensure uniform material melting in the joining zone, then welding quality is improved, but heat dissipates and heats the components outside the joining zone
Solution Approach 1:
The patent applies dynamics by continuously adapting the welding force during the process based on real-time monitoring of welding variables. The control system adjusts the force dynamically to maintain optimal welding conditions throughout the process, ensuring uniform melting while minimizing heat spread to surrounding areas.
Solution Approach 2:
The patent implements feedback control by monitoring welding variables (force, power, welding time, welding path, energy) and using this information to adjust the welding process in real-time. This closed-loop control ensures the welding process maintains optimal parameters to achieve quality welds while controlling heat dissipation.
2Temperature
If the welding process is accelerated to minimize heat dissipation, then heat control is improved, but welding quality may deteriorate due to insufficient melting time
Solution Approach 1:
The welding force is dynamically adjusted during the process based on monitored variables. When melting progresses as expected, the system can maintain or reduce force to control heat. When melting is insufficient, the system increases force to ensure proper welding, thus maintaining quality while controlling heat.
Solution Approach 2:
Real-time monitoring of welding variables provides feedback that enables the control system to adjust the welding process speed and force. This ensures the welding proceeds fast enough to minimize heat dissipation but slow enough to achieve complete melting and high-quality welds.
3Device complexity
If a single welding force is applied throughout the process, then device complexity is reduced, but welding quality varies due to changing material conditions during welding
Solution Approach 1:
The system dynamically adjusts the welding force during the process based on monitored variables such as power consumption, welding time, and welding path. This dynamic adaptation allows the welding force to match changing material conditions (solid, melting, molten states) to ensure consistent weld quality without requiring complex manual intervention.
Solution Approach 2:
The welding system performs self-adjustment by automatically modifying welding parameters based on real-time monitoring of the welding process. The control system uses feedback from sensors to autonomously optimize the welding force, eliminating the need for external manual adjustments and maintaining consistent quality.
4Manufacturing precision
If welding force is increased to ensure complete melting, then welding quality is improved, but components with sensitive geometries may be damaged
Solution Approach 1:
The welding force is dynamically adjusted based on the actual welding progress and material state. The system applies higher force only when and where needed to achieve complete melting, while reducing force during phases where high force could damage sensitive component geometries, thus protecting component integrity while ensuring weld quality.
Solution Approach 2:
The control system applies different welding forces to different locations and time periods during the welding process. By monitoring local conditions at the joining zone, the system applies sufficient force locally to achieve melting while avoiding excessive force that could damage other parts of the components with sensitive geometries.
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 approach enables a reliable and reproducible welding process by maintaining consistent welding variables in each interval, optimizing energy delivery and force application to achieve high-quality welds while minimizing heat dissipation outside the joining zone, thus improving the overall welding efficiency and consistency.
Implementation Method 1
The generator produces an electric alternating voltage, which is converted with the aid of the converter into a mechanical vibration
Implementation Method 2
boundary surface friction occurs between the two components in the so-called joining or welding zone and, as a result, local heating of the boundary surfaces occurs
Implementation Method 3
The converter in turn makes the sonotrode connected therewith carry out an ultrasonic vibration
Implementation Method 4
If the heating is so great that the boundary surfaces melt, the two components are welded
Data Source
AI summary
Invention relating to a method for controlling an ultrasonic machining, in which an ultrasonic vibration is transmitted via a sonotrode into the material to be machined. During the first machining interval, a first welding variable of the group S, consisting of the frequency f and the amplitude ü of the ultrasonic vibration, the force F, which the sonotrode exerts on the material to be machined, the power P, which the generator delivers, and the speed v, with which the sonotrode is moved in the direction of the material to be machined, is kept constant until a first target variable of the group Z adopts a predetermined value. During an adjoining second machining interval, a second welding variable of the group S is kept constant until a second target variable of the group Z adopts a predetermined value, wherein the first and the second target variable differ.