Ultrasonic Welding Horn Pressure Feedback for Variable Tab Thickness
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Solution Overview
Problem
Existing welding technologies struggle to maintain consistent pressure applied by the horn during ultrasonic welding, which affects the quality of the welds in secondary battery electrode assemblies.
Innovation Solution
A welding pressure control system that feedback-controls the ascent and descent of the horn based on pressure values sensed during its movement, using a sensing unit and control unit to maintain optimal pressure through a motor-driven elevating unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is provided at the lower side of the anvil to obtain pressure values, then pressure measurement is enabled, but the pressure cannot be substantially controlled during welding
Solution Approach 1:
The patent implements feedback control by using the pressure sensor to continuously monitor the pressure applied by the horn during welding, and the control unit adjusts the horn's position based on the sensed pressure values to maintain optimal welding pressure throughout the process
Solution Approach 2:
The patent replaces manual or open-loop mechanical pressure control with an automated control system that uses electronic sensing and control to regulate pressure, substituting mechanical adjustment methods with a feedback-based control mechanism
2Manufacturing precision
If the horn position is fixed to maintain constant pressure, then welding quality is improved, but adaptability to different welding subject thicknesses is reduced
Solution Approach 1:
The patent makes the horn position dynamic rather than fixed, allowing the horn to ascend and descend automatically in response to pressure feedback, enabling the system to adapt to varying welding subject thicknesses while maintaining constant welding pressure through real-time position adjustments
3Reliability
If real-time pressure sensing and control is implemented, then welding pressure is optimized, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into existing components: the pressure sensor serves both as a measurement device and a feedback source for control, the elevating unit both positions the horn and enables pressure regulation, and the control unit both monitors and adjusts the welding process, reducing the need for separate dedicated components for each function
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
The system optimizes welding efficiency by controlling pressure in real-time, reducing defects such as electrode tab folding and improving workability by accurately measuring and adjusting the pressure applied during the welding process.
Implementation Method 1
a sensing unit that senses a pressure value varying depending on the ascent and the descent of the horn
Implementation Method 2
the elevating unit includes a motor, a screw that receives driving power from a rotary axis of the motor and rotates, a vertically movable part that is coupled to the screw and moves vertically during the rotation of the screw
Implementation Method 3
The ultrasonic welding is a method of performing welding in such a manner that vibrational energy is selectively applied to a horn according to a control signal of a computer to allow the horn to be in contact with and press welding subjects
Implementation Method 4
frictional heat is generated through ultrasonic vibrations
Data Source
AI summary
A welding pressure control system includes: an anvil on which a welding subject is supported; a horn that presses the welding subject; an elevating unit that supports the horn to be ascendable and descendable; a sensing unit that senses a pressure value varying depending on the ascent and the descent of the horn; and a control unit that controls the elevating unit based on the pressure value obtained from the sensing unit. The elevating unit includes a motor, a screw that receives driving power from a rotary axis of the motor and rotates, a vertically movable part that is coupled to the screw and moves vertically during the rotation of the screw, and a support that is coupled to the vertically movable part and supports the horn. The sensor is disposed circumferentially about the screw and pressed according to the vertical movement of the vertically movable part.