Ultrasonic Welding Stop Element for Precise Cable Splice Positioning
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Solution Overview
Problem
Conventional ultrasonic welding devices require complex manual positioning of cables, which can lead to inconsistent weld quality and increased operational time, especially when switching between end and inline splices.
Innovation Solution
An ultrasonic welding device with a displaceable stop element and drive device that automatically adjusts the receiving chamber's configuration to facilitate precise alignment of cables, allowing for easy operation and consistent weld quality by defining a fifth side of the receiving chamber to ensure accurate positioning of cable ends or inline splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning of cables is used in conventional ultrasonic welding devices, then the device structure remains simple, but the positioning precision and weld quality consistency deteriorate
Solution Approach 1:
The stop element is made displaceable between a pulled-in position (defining the receiving chamber boundary) and a pulled-out position (allowing cable insertion). This dynamic positioning enables automatic cable alignment without complex manual adjustment mechanisms, resolving the contradiction between positioning precision and device complexity
Solution Approach 2:
The drive device automatically displaces the stop element to the pulled-in position after cable insertion, causing the cable end to abut against the stop element and achieve precise alignment. This self-aligning mechanism eliminates the need for complex manual positioning systems while ensuring consistent weld quality
2Productivity
If manual positioning of cables is used, then the device structure remains simple, but the operational time increases
Solution Approach 1:
The stop element is pre-positioned in the pulled-in position to define the receiving chamber boundary before cable insertion. After the operator inserts the cable, the drive device automatically displaces the stop element to abut against the cable end, achieving precise alignment without requiring the operator to perform time-consuming manual positioning adjustments
Solution Approach 2:
The manual mechanical positioning process is replaced by an automated drive device that displaces the stop element. This substitution eliminates the time-consuming manual adjustment step while adding only a simple actuation mechanism, thereby improving productivity without significantly increasing device complexity
3Adaptability or versatility
If a fixed stop element is used to define the receiving chamber, then cable positioning is simplified, but the adaptability for different splice types deteriorates
Solution Approach 1:
The stop element transitions from a fixed position to a displaceable position, allowing it to be pulled in to define the receiving chamber boundary for one type of splice and pulled out to allow cable insertion for another type. This dynamic adaptability enables the device to handle different splice types (end splices and inline splices) while maintaining ease of operation through automated control
Solution Approach 2:
The displaceable stop element serves multiple functions: it defines the receiving chamber boundary when pulled in, allows cable insertion when pulled out, and provides an abutment surface for automatic cable alignment. This multi-functionality enables the device to accommodate different splice types without requiring separate positioning mechanisms for each type
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 device simplifies the welding process, reduces manual intervention, and ensures consistent weld quality by automatically adjusting the stop element's position based on the type of splice required, minimizing the need for manual alignment and reducing setup times.
Implementation Method 1
the vibrations may be generated with the aid of a sonotrode in which ultrasonic vibrations with frequencies of typically 20 kHz to 50 kHz are generated and transmitted to at least one of the joining partners
Implementation Method 2
The drive device is configured to actively displace the first stop element between the pulled-in position and the pulled-out position
Data Source
AI summary
An ultrasonic welding device includes a sonotrode, an anvil, a touching element, a lateral slide, a first stop element, a drive device, and a receiving chamber in which joining partners are to be received. The receiving chamber is defined on a first side by a surface of the sonotrode and on a second side opposing the first side by a surface of the anvil. The receiving chamber is further defined on a third side by a surface of the touching element and on a fourth side opposing the third side by a surface of the lateral slide. The first stop element is displaceable between a pulled-in position and a pulled-out position. The first stop element in the pulled-in position defines the receiving chamber on a fifth side extending transverse to the first to fourth sides and in the pulled-out position leaves the receiving chamber open on the fifth side.