Ultrasonic Welding Apparatus Knife Drive Relocation
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Solution Overview
Problem
Existing devices for welding rod-shaped conductors with a knife device for cutting defective welds increase in external dimensions and restrict conductor handling due to the arrangement of the drive motor and installation space, making precise positioning difficult.
Innovation Solution
The drive motor is positioned below the sonotrode, connected via a deflection gear to the blade holder, allowing only the functional parts of the knife device to protrude in front of the compression chamber, maintaining the device's dimensions and enabling easier handling of conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive motor and installation space are arranged adjacent to the compression space in the x-axis direction, then the knife device can effectively cut defective welds, but the device dimensions in the x-axis direction increase and conductor handling becomes more difficult
Solution Approach 1:
The drive motor is relocated from the x-axis direction to the z-axis direction (below the sonotrode), changing the spatial arrangement from horizontal to vertical. This dimensional shift allows the knife device to maintain its cutting function while eliminating the need for additional x-axis installation space, thus resolving the contradiction between reliability and device footprint.
Solution Approach 2:
Instead of arranging the drive motor adjacent to the compression space in the conventional x-axis direction, the invention inverts the arrangement by positioning it below the sonotrode in the z-axis direction. This inverted spatial configuration maintains the knife device's operational effectiveness while improving conductor accessibility and reducing the device's external dimensions.
2Reliability
If the drive motor and installation space are arranged adjacent to the compression space in the x-axis direction, then the knife device can effectively cut defective welds, but the handling distance between the outer contour and compression space increases, making precise positioning more difficult
Solution Approach 1:
By relocating the drive motor to the z-axis direction (below the sonotrode), the invention changes the spatial arrangement from horizontal (x-axis) to vertical (z-axis). This dimensional change reduces the handling distance between the outer contour and compression space, improving conductor accessibility and positioning ease while maintaining the knife device's defective weld cutting capability.
3Length of stationary object
If only the functional parts of the knife device are arranged in front of the compression chamber, then the device dimensions are maintained, but the drive motor requires an alternative installation space
Solution Approach 1:
The drive motor is installed in the z-axis direction (below the sonotrode) instead of the x-axis direction, utilizing previously unused vertical space. This dimensional relocation maintains the device's external dimensions while providing a practical installation location for the drive motor, thus resolving the contradiction between compact dimensions and drive motor installation requirements.
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 configuration allows for effective cutting of defective welds without increasing the device's dimensions, improving accessibility and handling of conductors during the welding process.
Implementation Method 1
the compression space 12 in the direction of a z-axis being oscillated on two opposite sides by a working surface of ultrasonic vibrations in the direction of an x-axis transmitting sonotrode
Implementation Method 2
the connection areas 13 of the conductors 14 are then subjected to mechanical vibrations of the sonotrode 16 in such a way that the connection areas 13 are compressed and connected to one another in a friction welding process
Data Source
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AI summary
The invention relates to an apparatus for welding together bar-shaped conductors (14), comprising a compression chamber for accommodating joining sections (13) of the conductors that are to be joined together; in a first axial direction (z axis), the compression chamber is delimited on two opposite sides by an active surface of a sonotrode (16) transmitting ultrasonic vibrations in the direction of the z axis and an opposite surface of a counter electrode (18). The apparatus further comprises a knife mechanism which is provided with a driving device and a knife (24) that can slide in the direction of the z axis and has a cutting edge which can move past the compression chamber. A drive motor of the driving device is located in a mounting space below the sonotrode and is connected to a knife holder (26) via a deflection gear in order for the knife to be able to perform a cutting movement, the knife holder being able to slide in the direction of the z axis.