Ultrasonic Welding Device with Integrated Shear Testing Head
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Solution Overview
Problem
Mechanical testing of terminal connections after the welding process is inefficient, as it requires additional handling and only a limited number of connections can be checked due to the associated effort, leading to potential undetected faults in mechanical loads.
Innovation Solution
A device with a test head that can be pivoted into the compression space to apply a shearing force to the welded connection within the compression space, eliminating the need for separate handling and allowing for increased testing without prolonging production time, using the side-shift element's infeed device for the test head's infeed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical stress tests are performed after welding by removing connection assemblies from the compression chamber, then the weld joint can be tested for mechanical strength, but additional handling is required and only a small number of connections can be checked efficiently
Solution Approach 1:
The patent combines the welding process and mechanical testing process into a single integrated system. The compression chamber serves dual purposes: it compresses contact partners during ultrasonic welding and subsequently holds them for mechanical shear testing. This eliminates the need to remove connection assemblies from the compression chamber between welding and testing, thereby increasing the number of connections that can be tested per batch without requiring additional handling steps.
Solution Approach 2:
The compression chamber is designed to perform multiple functions: it serves as the welding chamber during ultrasonic welding and as the testing chamber during mechanical shear testing. The same physical structure and positioning mechanisms are used for both processes, allowing the system to transition between welding mode and testing mode without requiring separate equipment or additional handling of the connection assemblies.
2Reliability
If mechanical stress tests are performed after welding by removing connection assemblies, then testing can be conducted, but the associated handling effort increases production time
Solution Approach 1:
The connection assemblies are positioned and compressed in the compression chamber during the welding process, and this positioning is maintained for the subsequent testing process. By preparing the connection assemblies in advance within the compression chamber and maintaining their position, the patent eliminates the need for time-consuming removal and repositioning operations between welding and testing, thereby reducing production time per batch.
Solution Approach 2:
By merging the welding and testing operations into a single continuous process within the compression chamber, the patent eliminates the time loss associated with removing connection assemblies from the compression chamber and performing separate handling operations. The integrated system allows welding and testing to be performed sequentially without interruption or additional handling time.
3Reliability
If a separate handling process is used for mechanical testing, then testing can be performed, but the complexity of the overall process increases
Solution Approach 1:
The compression chamber and its associated positioning mechanisms are designed to serve dual purposes: welding and mechanical testing. By using the same physical structure and control systems for both operations, the patent reduces device complexity compared to having separate welding and testing equipment. The system transitions between modes using the existing infrastructure, eliminating the need for additional complex handling mechanisms.
Solution Approach 2:
The compression chamber automatically maintains the connection assemblies in position for both welding and testing operations. The same clamping and positioning mechanisms that hold the contact partners during welding continue to hold them during testing, eliminating the need for separate handling devices or additional positioning systems. The system serves itself by using its existing structures for multiple functions.
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 efficient mechanical testing of terminal connections in situ, significantly increasing the number of connections checked without adding to production time, ensuring reliability by identifying and severing or reshaping faulty connections.
Implementation Method 1
a working surface of an ultrasonic vibration-transmitting sonotrode
Implementation Method 2
for applying a shearing force directed substantially parallel to the welding plane to the other contact partner
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a device and to a method for producing a tested weld joint between two contact partners (11, 12), which are joined to each other in a welding plane S, comprising a compression chamber for accommodating the contact partners (11, 12), wherein the compression chamber is bounded in a first axial direction at two sides lying opposite each other by a working surface of a sonotrode, which sonotrode transmits ultrasonic oscillations, and by a counter-surface (15) of a counter-electrode (16) and in a second axial direction at two sides lying opposite each other by bounding surfaces of bounding elements, which bounding elements lie opposite each other, wherein the device has a testing head (27) adjacent to the compression chamber, and the testing head can be transferred from a position outside of the compression chamber to a position within the compression chamber in such a way that, in a testing mode of the device for applying a shear force directed substantially parallel to the welding plane S to one contact partner (12) of the previously produced weld joint, the testing head (27) is arranged within the opened compression chamber and, in a welding mode of the device for producing the weld joint, the testing head (27) is arranged outside of the compression chamber.