Ultrasonic Welding Device Optical Positioning Rod Conductors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for welding rod-shaped electrical conductors struggle to maintain precise geometric specifications in weld nodes, leading to potential short circuits due to incomplete compression or welding, especially in cable installations where defined distances between conductor ends and insulating coverings are critical.
Innovation Solution
A device with a marking system using a radiation emission device that creates a position mark on the sonotrode or boundary element, allowing for axial positioning of conductor ends without mechanical contact, ensuring accurate alignment and defined distances for reliable weld node formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical contact positioning is used to position conductor ends in the compression space, then positioning can be achieved, but the geometric specifications of weld nodes cannot be precisely maintained
Solution Approach 1:
The patent replaces mechanical contact positioning with an optical marking system. A radiation emission device projects a light pattern (e.g., crosshair or plus sign) onto the compression space, creating visual position marks that guide conductor end placement. This optical system substitutes for mechanical stops or fixtures, enabling precise positioning without mechanical contact, thereby maintaining weld node geometric specifications and preventing filament protrusion that could cause short circuits.
2Ease of operation
If defined distances between conductor ends and insulating coverings are not precisely maintained, then positioning is simpler, but filaments protrude radially causing short circuits
Solution Approach 1:
The patent introduces an optical marking system as an intermediary between the conductor ends and the compression space boundaries. The radiation emission device projects position marks that serve as visual intermediaries, guiding operators to place conductor ends at precise locations without requiring direct measurement or complex mechanical positioning. This intermediary optical system maintains defined distances between conductor ends and insulating coverings, preventing filament protrusion while keeping the operation simple.
3Productivity
If compression and welding are incomplete, then the process is faster, but weld node quality deteriorates leading to short circuits
Solution Approach 1:
The patent implements preliminary positioning action through the optical marking system before the actual compression and welding process. The radiation emission device projects position marks that allow conductor ends to be pre-positioned accurately in the compression space. This preliminary optical positioning ensures that when compression and welding occur, the conductor ends are already correctly aligned, enabling complete and high-quality weld nodes without requiring repositioning or repeated attempts, thus maintaining both productivity and weld node quality.
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 solution enhances the reliability of cable installations by ensuring precise axial positioning of conductor ends, preventing radially protruding filaments and improving the quality of ultrasonic weld joints, thus reducing the risk of short circuits.
Implementation Method 1
a radiation emission device which interacts without contact with end cross sections of the connection areas in such a way that the axial position of the end cross sections within the compression space is defined by a position mark designed as a reflection point or absorption point of the radiation
Implementation Method 2
a working surface of a sonotrode transmitting ultrasonic vibrations in the first axis direction
Data Source
Figure 1~2
Figure 3~8
Figure 9
AI summary
The invention relates to a device for the welding of rod-type electrical conductors that have an outer insulating sheath, comprising a compression space for receiving two joining regions of the conductors, wherein the compression space is provided with a marking arrangement for axial positioning of the joining regions, wherein the marking arrangement has a radiation-emitting arrangement that defines a position mark (56, 57).