Ultrasonic Welding Control Signal Analysis for Weld Status Tracking
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Solution Overview
Problem
Current ultrasound welding processes lack effective methods for assessing the quality and state of the welding process without interfering with the system or altering the welding conditions, particularly in determining the impact of varying weld settings and conditions on the control variables like frequency.
Innovation Solution
A device and method using a sensor element to measure electrical control signals from an ultrasound tool, with an evaluation unit that determines signal properties based on a reference signal profile, allowing for non-invasive monitoring of current and voltage during welding, and using Fourier analysis to analyze temporal relationships and harmonic distortions, enabling system-independent diagnosis of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measurement methods are introduced to assess welding process quality, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces an evaluation unit as an intermediary component that measures electrical control signals (voltage and current) without directly interfering with the welding process. This mediator approach allows quality assessment through indirect measurement of process parameters, resolving the contradiction by providing measurement capability while maintaining system simplicity.
Solution Approach 2:
The patent replaces complex mechanical or direct physical measurement systems with electrical signal analysis. By measuring electrical control signals and analyzing their properties (amplitude, frequency, phase) to infer welding quality, the system achieves precise measurement without complex mechanical intervention in the welding process.
2Reliability
If non-invasive measurement of control signals is implemented, then reliability is improved by not affecting the welding process, but measurement precision may be compromised
Solution Approach 1:
The patent implements feedback by continuously monitoring electrical control signals and using the measured properties to assess welding process quality. The evaluation unit analyzes voltage and current signals in real-time, providing feedback information about process state without disrupting the process, thus maintaining both reliability and measurement precision.
Solution Approach 2:
By using electrical signal measurement as an intermediary method, the system obtains precise measurement data without direct contact or interference with the welding zone. The electrical signals serve as a mediator that carries information about the welding process state while remaining unaffected by the high-energy welding environment.
3Adaptability or versatility
If system-independent diagnosis is implemented, then adaptability is improved for different ultrasound systems, but device complexity increases
Solution Approach 1:
The patent achieves system independence by designing an evaluation unit that measures universal electrical parameters (voltage and current) that are common to all ultrasound welding systems. By focusing on these universal electrical control signals rather than system-specific mechanical or acoustic parameters, the device gains broad adaptability across different ultrasound generators and tools without requiring system-specific customization.
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 the characterization of the vibration system and assessment of weld quality without affecting the welding process, allowing for adjustments in control variables like frequency based on real-time measurements, thereby improving the reliability and efficiency of the ultrasound welding process.
Implementation Method 1
a sensor element, which is designed to detect an electrical control signal of the ultrasound tool
Implementation Method 2
The use of a Fourier analysis can comprise a short-term Fourier analysis, from which the temporal relationships of the amplitude, frequency or other quantities can be determined
Implementation Method 3
Ultrasound welding processes for metals use ultrasound tools (or also US vibration systems) for welding of different metal pairings
Implementation Method 4
During the weld process there are various phases of cleaning-, diffusion- and bonding-processes
Data Source
AI summary
A device to determine a state of an ultrasound welding process, which can be carried out using an ultrasound tool, includes a sensor element and an evaluation unit. The sensor element is configured to detect an electrical control signal from an ultrasound tool. The evaluation unit is configured to determine a signal property of the control signal and to determine the status of the ultrasound welding process based on a reference signal profile and on the determined signal property. An assembly with an ultrasound welding system and a method are also included.