V-Shaped Ultrasonic Welding Receptacle for Inline Splice Alignment
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Solution Overview
Problem
Existing ultrasonic welding devices require significant operator effort to correctly position joining parts, such as cable ends, for efficient welding, especially for inline splices, as precise alignment is crucial to prevent side-by-side placement and ensure strong, conductive bonds.
Innovation Solution
The ultrasonic welding device incorporates a sonotrode, lateral slide, and touching element with movable receiving elements forming a v-shaped receptacle, allowing for easy insertion and alignment of parts, with a drive device and control system to adjust the receptacle's shape and position based on the parts' cross-section, ensuring optimal positioning and minimizing manual operation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning of joining parts is used, then operator skill level determines positioning accuracy, but this increases operation complexity and reduces productivity
Solution Approach 1:
The joining parts themselves perform the positioning function by being guided into the V-shaped receptacle geometry. The V-shape causes parts to nestle and align automatically based on their own dimensions, eliminating the need for operator skill in positioning
Solution Approach 2:
The V-shaped receptacle changes the geometric parameters of the positioning system from flat surfaces to angled surfaces that converge. This geometric parameter change creates natural alignment forces that guide parts into correct positions
2Manufacturing precision
If manual positioning of joining parts is used, then operator skill level determines positioning accuracy, but this increases time consumption
Solution Approach 1:
The V-shaped receptacle performs preliminary positioning action before the welding process begins. Parts are pre-aligned as they are inserted into the receptacle, eliminating the need for time-consuming manual adjustment during operation
Solution Approach 2:
The geometry of the V-shaped receptacle enables parts to self-align and self-position automatically during insertion, reducing the time operators need to spend on positioning while maintaining high precision
3Ease of operation
If fixed receptacle geometry is used, then positioning is simple, but adaptability to different part cross-sections is reduced
Solution Approach 1:
The receptacle geometry is made variable and adjustable rather than fixed. The ability to change the V-shape angle and dimensions allows the same receptacle to adapt to different part cross-sections while maintaining simple positioning operation
Solution Approach 2:
The adjustable V-shaped receptacle serves multiple functions: it can accommodate different part cross-sections, adjust to different welding configurations, and maintain simple positioning across all variations, making it a universal positioning solution
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 design simplifies the insertion process, allowing even less skilled operators to position parts efficiently, ensuring the largest cross-section part is aligned correctly on the sonotrode, while others are stacked on top, enhancing welding efficiency and consistency.
Implementation Method 1
a sonotrode (102) with a sonotrode surface (112), ... in which ultrasonic vibrations with frequencies of typically 20 kHz to 50 kHz are generated and transmitted to at least one of the joining partners
Implementation Method 2
This is a special form of friction welding in which components to be welded, also referred to as joining partners or weld metal, are brought into surface contact with each other and moved against each other under low pressure and high-frequency mechanical vibrations
Implementation Method 3
the joining part receptacle is v-shaped in order to position the joining parts in the insertion chamber (108) in the first axial direction and in a second axial direction
Data Source
AI summary
An ultrasonic welding device includes a sonotrode with a sonotrode surface, a lateral slide with a lateral slide surface, a touching element with a touching surface and an insertion chamber for inserting joining parts. The insertion chamber is defined in a first axial direction (y) on a first side by the sonotrode surface and in a second axial direction (x) on a second side by the lateral slide surface and on a third side opposing the second side by the touching surface. Furthermore, the ultrasonic welding device includes a first receiving element with a first stop edge and a second receiving element with a second stop edge. The first receiving element and the second receiving element are arranged to be movable in relation to each other between a starting position and an end position.