Ultrasonic Welding Control for Continuous Multi-Layer Sealing
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Solution Overview
Problem
Existing ultrasonic welding processes are unsuitable for the continuous sealing of individual containers, often causing damage to the container edges or failing to create a sealed weld, and discontinuous processes are inefficient for integration into flow production.
Innovation Solution
A method and device that control and vary welding parameters such as amplitude, force, and gap width during the ultrasonic welding process, adapting to the presence or absence of a product in the gap to prevent edge damage and ensure a secure seal, using a generator, anvil, sonotrode, and conveyor system with sensors for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous ultrasonic welding process is used, then productivity is improved, but edge damage occurs and sealing reliability deteriorates
Solution Approach 1:
The patent applies dynamics by making the welding parameters (amplitude, force, gap width) variable during the welding process. The control device adjusts these parameters in real-time based on the product position and movement state, transitioning from static to dynamic control. This enables the system to adapt to different welding stages (approach, contact, welding, separation) and prevents edge damage while maintaining sealing quality in continuous production.
Solution Approach 2:
The patent implements parameter changes by varying welding parameters such as amplitude, force, and gap width during the welding process. The control device modifies these parameters based on detected product position and movement state, enabling optimization of welding quality at different stages and preventing edge damage while maintaining high productivity.
2Device complexity
If constant welding parameters are used, then device complexity is reduced, but manufacturing precision deteriorates due to edge damage
Solution Approach 1:
The patent applies feedback by using sensors to detect product position and movement state, then feeding this information back to the control device. The control device uses this feedback to automatically adjust welding parameters in real-time, creating a closed-loop control system that maintains manufacturing precision without requiring overly complex manual intervention.
Solution Approach 2:
The system implements self-service by automatically detecting product position and adjusting welding parameters without external intervention. The control device autonomously manages the welding process based on sensor input, reducing the need for operator complexity while maintaining precise edge integrity.
3Reliability
If discontinuous welding process is used, then sealing reliability is improved, but productivity deteriorates
Solution Approach 1:
The patent implements continuity of useful action by maintaining the welding process in continuous operation while dynamically adjusting parameters for each product. The system eliminates idle time between products by keeping the ultrasonic tool engaged and ready, switching parameters smoothly as products arrive and depart, thus maintaining high productivity with reliable sealing.
4Reliability
If welding parameters are increased to ensure seal quality, then sealing reliability is improved, but edge damage worsens
Solution Approach 1:
The patent applies local quality by applying different welding parameters to different regions and stages of the welding process. High amplitude and force are applied only during the actual welding contact phase when the product is properly positioned, while lower parameters are used during approach and separation phases. This localized parameter application ensures reliable sealing at the weld seam while preventing damage to edge areas.
Solution Approach 2:
The patent implements periodic action by cycling through different welding parameter states corresponding to different process phases (approach, contact, welding, separation). The control device periodically adjusts parameters based on product position and contact detection, applying high energy only during the brief welding contact phase and reducing energy during other phases to prevent edge damage.
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
Enables rapid, safe, and efficient continuous welding of multi-layer products without edge damage, achieving a tight seal by varying welding parameters based on product position and movement, suitable for sealing bags and similar packaging.
Implementation Method 1
the sonotrode is excited by the generator such that it oscillates with a predetermined amplitude and transmits the oscillation to the product
Implementation Method 2
The (separated) product is welded by the ultrasonic tool during its movement along a welding path by pressing the sonotrode and/or anvil against the product with a force
Data Source
Figure 1
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Figure 2
AI summary
Method and device for welding a separated, multi-layer product.