Ultrasonic Welding Head Control With Separate Lowering and Pressurizing
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Solution Overview
Problem
Conventional ultrasonic vibration welding apparatuses face difficulties in controlling the lifting-lowering and pressurizing operations due to the need for two detection processes using a pressure sensor, making it challenging to achieve precise and efficient welding.
Innovation Solution
The ultrasonic vibration welding apparatus incorporates a separate pressurizing mechanism, such as an air cylinder, and a lowering mechanism, allowing for individual control of the lowering and pressurizing operations, eliminating the need for a pressure sensor to detect the pressurizing force and enabling constant and accurate pressurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single lifting-lowering pressurizing servomotor is used to perform both lowering and pressurizing operations, then the device structure is simplified, but the control complexity increases due to the need for two detection processes using a pressure sensor
Solution Approach 1:
The patent divides the combined lifting-lowering pressurizing mechanism into separate components: a lifting-lowering mechanism and a pressurizing mechanism. This segmentation allows each mechanism to perform its dedicated function independently, simplifying control logic while maintaining structural efficiency. The lifting-lowering servomotor solely controls vertical movement, while the pressurizing mechanism independently applies force, eliminating the need for complex dual-detection control processes.
Solution Approach 2:
The patent introduces a position detection unit as an intermediary component that detects the contact state between the ultrasonic welding portion and the welding target. This intermediary detection method replaces the need for complex pressure sensor-based dual detection processes, providing simple positional information that enables straightforward control of both lowering and pressurizing operations without increasing control complexity.
2Measurement precision
If a pressure sensor is used to detect welding contact state and pressurizing force, then measurement capability is provided, but the operating time increases due to the need for two detection processes
Solution Approach 1:
The patent introduces a position detection unit that detects the contact state between the ultrasonic welding portion and the welding target by monitoring positional changes. This intermediary detection approach provides the necessary measurement capability for welding contact state without requiring complex pressure sensor-based dual detection processes, thereby reducing operating time while maintaining adequate detection precision.
Solution Approach 2:
The patent replaces pressure sensor-based mechanical detection with a position detection system that monitors the vertical position of the ultrasonic welding head. This substitution eliminates the need for force measurement, reducing the number of detection processes from two (contact state and force magnitude) to one (position), thereby significantly reducing operating time while providing sufficient control information.
3Difficulty of detecting and measuring
If pressure sensor-based detection is used for welding contact state, then detection capability is achieved, but the device complexity and operating time increase
Solution Approach 1:
The patent replaces pressure sensor-based mechanical force detection with a position detection system that monitors the vertical position of the ultrasonic welding head. This substitution simplifies the detection mechanism by eliminating force measurement requirements, reducing device complexity in the control process while maintaining adequate detection capability for welding contact state through positional information.
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 configuration allows for easier and more precise control of the welding process, reducing the operating time and enabling accurate detection of the welding contact state without the need for a pressure sensor, thus improving the efficiency and accuracy of the ultrasonic welding process.
Implementation Method 1
an ultrasonic welding head unit which executes an ultrasonic vibration operation of applying ultrasonic vibrations from an ultrasonic welding portion
Implementation Method 2
a pressurizing mechanism which executes a pressurizing operation of applying a pressurizing pressing force to the ultrasonic welding head unit toward the table side
Data Source
AI summary
An ultrasonic vibration welding apparatus includes an air cylinder that is coupled to an ultrasonic welding head unit and executes a pressurizing operation of pressurizing on the ultrasonic welding head unit, and a lifting-lowering servomotor that executes a lifting-lowering operation including a lowering operation of lowering the ultrasonic welding head unit and the air cylinder at once, as components separate from each other.