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US 10,105,787 B2Granted
Systems and methods for ultrasonic welding
AssigneeGM Global Technology Operations LLC
InventorsPei-chung Wang, Susan M. Smyth, Zhongxia Liu
Life of this patent
Estimating the term…
Abstract
Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.
Claims20
A method, comprising:
- applying, by a horn as controlled by a controller, a first pulse of ultrasonic vibration to a first workpiece and a second workpiece until a measured value meets or exceeds a preset threshold value, wherein the first pulse of ultrasonic vibration is applied to a first workpiece and a second workpiece at an overlapping portion of the workpieces;
- measuring, over time during the first pulse, by the controller, a dissipated power and a horn position;
- determining, by the controller:
- a duration of a stage as a difference between:
- an end time of the stage based on a time when the controller stops ultrasonic vibration;
- and
- a start time of the stage based on a drop in the dissipated power over time;
- a horn displacement during the stage based on a difference between:
- a first horn position measured at the start time of the stage;
- and
- a second horn position measured at the end time of the stage;
- wherein the horn position over time includes the first horn position and the second horn position;
- and
- a weld strength value based on weld strength data, the duration of the stage, and the horn displacement during the stage;
- and
- comparing, by the controller, the weld strength value to a threshold weld strength value.
13 more elements
A system, comprising:
- a horn;
- a controller, configured to:
- apply, by the horn, a first pulse of ultrasonic vibration to the workpieces until a measured value meets or exceeds a preset threshold value;
- measure, over time and during the first pulse, a dissipated power and a horn position;
- determine:
- a duration of a stage as a difference between:
- an end time of the stage based on a time when the controller stops ultrasonic vibration;
- and
- a start time of the stage based on a drop in the dissipated power over time;
- a horn displacement during the stage based on a difference between:
- a first horn position measured at the start time of the stage;
- and
- a second horn position measured at the end time of the stage,
- wherein the measured horn position includes the first horn position and the second horn position;
- and
- a weld strength value based on weld strength data, the duration of the stage, and the horn displacement during the stage;
- and
- compare the weld strength value to a threshold weld strength value.
15 more elements
A computer-readable medium comprising instructions that, when executed by a processor, cause the processor to:
- apply, by a horn, a first pulse of ultrasonic vibration to a first workpiece and a second workpiece until a measured value meets or exceeds a preset threshold value, wherein the first pulse of ultrasonic vibration is applied to a first workpiece and a second workpiece at an overlapping portion of the workpieces;
- measure, over time during the first pulse, a dissipated power and a horn position;
- determine:
- a duration of a stage as a difference between:
- an end time of the stage based on a time when the controller stops ultrasonic vibration;
- and
- a start time of the stage based on a drop in the dissipated power over time;
- a horn displacement during the stage based on a difference between:
- a first horn position measured at the start time of the stage;
- and
- a second horn position measured at the end time of the stage;
- wherein the measured horn position includes the first horn position and the second horn position;
- and
- a weld strength value based on weld strength data, the duration of the stage, and the horn displacement during the stage;
- and
- compare the weld strength value to a threshold weld strength value.
13 more elements
Dependencies are inferred from the claim text.