Ultrasonic Welding Machine Integrated Tensile Testing
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Solution Overview
Problem
Ultrasonic processing machines lack an efficient and cost-effective method for conducting tensile tests on welded components, requiring separate tensile testing machines and involving complex and time-consuming processes.
Innovation Solution
Integration of a receiving device for workpiece holders within the ultrasonic processing machine, allowing for seamless switching between processing and tensile test cycles, with a controller managing the transition and recording force and displacement data for quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tensile testing machines are used for quality assurance of welded components, then measurement precision and reliability are improved, but device complexity and loss of time increase
Solution Approach 1:
The patent combines the tensile testing function with the ultrasonic processing machine by integrating a carriage that can perform both welding operations and tensile tests. The carriage is equipped with a force measuring device and displacement measuring device, allowing the same equipment to execute both processing and quality assurance functions, thereby eliminating the need for separate testing machines and reducing time loss.
Solution Approach 2:
The ultrasonic processing machine is designed with multi-functionality, where the carriage can switch between performing ultrasonic welding/separating operations and conducting tensile tests on welded components. This universal design allows one machine to serve multiple purposes: processing and quality control, thus improving efficiency without compromising measurement precision.
2Measurement precision
If separate tensile testing equipment is used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The force measuring device and displacement measuring device are integrated into the carriage of the ultrasonic processing machine. This merging of measurement functions into the existing structure avoids the need for separate complex testing equipment while maintaining measurement precision through the use of dedicated sensors and control systems.
Solution Approach 2:
The ultrasonic processing machine performs its own quality control by using its integrated measuring devices to conduct tensile tests on the welded components it produces. The machine serves itself for both processing and quality assurance, eliminating the need for external testing equipment and reducing overall system complexity.
3Ease of operation
If manual switching between processing and testing is required, then ease of operation decreases, but device complexity is reduced
Solution Approach 1:
The controller is designed to dynamically switch between different operational modes (processing cycle and tensile test cycle) based on user input or automated conditions. This dynamic capability allows the machine to adapt its function in real-time, improving ease of operation by enabling seamless transitions between welding and testing without requiring manual reconfiguration or complex external controls.
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 simplified, cost-effective, and time-saving tensile testing directly on the processing machine, eliminating the need for separate testing equipment and allowing for automated quality control with minimal additional costs.
Implementation Method 1
a vibration generator, with which a sonotrode serving as a working element can be excited to high-frequency vibrations
Implementation Method 2
a force measuring device, with the help of which the drive of the slide and the vibration generator can be controlled in such a way that the working element is placed against the workpiece with a desired force profile
Implementation Method 3
a displacement measuring device, with the help of which the drive of the slide and the vibration generator can be controlled
Data Source
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AI summary
An ultrasonic machining machine comprises a stand that can be mounted on a base plate. The machine also features a vibration generator, which drives a working element. The vibration generator is supported by a slide that is slidable along the length of the stand. The slide, in turn, is supported by a linear actuator mounted on the stand. The vibration generator is aligned with the travel path of the linear actuator.