Ultrasonic Welding Horn Alignment Collar
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Solution Overview
Problem
The installation of an ultrasonic welder is hindered by the difficulty and time-consuming process of aligning the ultrasonic welding horn relative to the anvil.
Innovation Solution
A removable collar assembly with set screws is used to rotate the ultrasonic welding horn, ensuring it is aligned parallel to the anvil by contacting the housing, facilitating precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional alignment methods are used, then alignment accuracy can be achieved, but the process is time-consuming and difficult
Solution Approach 1:
The patent introduces a collar assembly as an intermediary device between the ultrasonic welding horn and the housing. This collar includes alignment features such as a flat surface on the horn and corresponding alignment surfaces on the collar, along with set screws that contact the housing to prevent rotation. This intermediary mechanism enables precise alignment without requiring complex traditional alignment procedures, thereby achieving high alignment accuracy while significantly reducing alignment time and operational difficulty
2Manufacturing precision
If traditional alignment methods are used, then alignment can be achieved, but the operation is difficult and complex
Solution Approach 1:
The collar assembly is designed with self-aligning features where the flat surface on the ultrasonic welding horn fits into corresponding alignment surfaces on the collar. The set screws automatically contact the housing to lock the horn in the correct rotational position. This self-service mechanism eliminates the need for complex manual alignment procedures, making the operation simple and easy while maintaining high alignment precision
Solution Approach 2:
The collar assembly serves as an intermediary that simplifies the alignment operation. By incorporating pre-designed alignment features and rotation-prevention mechanisms, it transforms a complex alignment task into a simple assembly operation, thereby improving ease of operation while maintaining manufacturing precision
Data Source
AI summary
An ultrasonic welding machine and method are provided. The machine includes an ultrasonic welding horn operably coupled to a housing. The machine further includes an anvil operably coupled to the housing. The machine further includes a removable collar assembly that is coupled around a portion of an outer surface of the ultrasonic welding horn. The removable collar assembly has at least first and second set screws that contact the housing such that when at least one of the first and second set screws are moved inwardly toward the housing, the removable collar assembly rotates the ultrasonic welding horn to align the ultrasonic welding horn relative to the anvil.