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US 10,105,789 B2Granted
Systems and methods for ultrasonic welding
AssigneeGM Global Technology Operations LLC
InventorsPei-chung Wang, Susan M. Smyth, Zhongxia Liu
Life of this patent
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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:
- determining fit-up conditions including a material of workpieces;
- determining a threshold weld strength value;
- accessing weld strength data, the weld strength data including a plurality of values of weld strength and a plurality of values of welding parameters, each of the plurality of values of weld strength corresponding to:
- a value of a first welding parameter of a first pulse of ultrasonic vibration;
- and
- a value of a second welding parameter of a second pulse of ultrasonic vibration;
- determining a weld schedule, comprising:
- selecting a first value of the first welding parameter of the first pulse of ultrasonic vibration;
- and
- selecting a second value of the second welding parameter of the second pulse of ultrasonic vibration;
- wherein each of the first value of the first welding parameter and the second value of the second welding parameter is selected based on:
- the weld strength data;
- the threshold weld strength value;
- and
- minimizing at least one of the first value of the first welding parameter and the second value of the second welding parameter;
- and
- applying, by a welding horn according to the weld schedule:
- the first pulse of ultrasonic vibration to workpieces, the first pulse having the first welding parameter;
- and
- after a cooling period, the second pulse of ultrasonic vibration to the workpieces, the second pulse having the second welding parameter.
17 more elements
A welding system, comprising:
- a welding horn;
- and
- a controller, comprising:
- a processor;
- and
- a memory, comprising:
- weld strength data including a plurality of values of weld strength and a plurality of values of welding parameters, each of the plurality of values of weld strength corresponding to:
- a value of a first welding parameter of a first pulse of ultrasonic vibration;
- and
- a value of a second welding parameter of a second pulse of ultrasonic vibration;
- computer executable instructions that, when executed by the processor, cause the processor to perform operations comprising:
- determining fit-up conditions including a material of workpieces;
- determining a threshold weld strength value;
- accessing the weld strength data,
- determining a weld schedule, comprising:
- selecting a first value of the first welding parameter of the first pulse of ultrasonic vibration;
- and
- selecting a second value of the second welding parameter of the second pulse of ultrasonic vibration;
- wherein each of the first welding parameter and the second welding parameter is selected based on:
- the weld strength data;
- the threshold weld strength value;
- and
- minimizing at least one of the first value of the first welding parameter and the second value of the second welding parameter;
- and
- applying, by the welding horn according to the weld schedule:
- the first pulse of ultrasonic vibration to workpieces;
- and
- after a cooling period, the second pulse of ultrasonic vibration to the workpieces.
25 more elements
A controller, comprising:
- a processor;
- and
- a memory, comprising:
- weld strength data including a plurality of values of weld strength and a plurality of values of welding parameters, each of the plurality of values of weld strength corresponding to:
- a value of a first welding parameter of a first pulse of ultrasonic vibration;
- and
- a value of a second welding parameter of a second pulse of ultrasonic vibration;
- computer executable instructions that, when executed by the processor, cause the processor to perform operations comprising:
- determining fit-up conditions including a material of workpieces;
- determining a threshold weld strength value;
- accessing the weld strength data,
- determining a weld schedule, comprising:
- selecting a first value of the first welding parameter of the first pulse of ultrasonic vibration;
- and
- selecting a second value of the second welding parameter of the second pulse of ultrasonic vibration;
- wherein each of the first welding parameter and the second welding parameter is selected based on:
- the weld strength data;
- the threshold weld strength value;
- and
- minimizing at least one of the first value of the first welding parameter and the second value of the second welding parameter;
- and
- applying, by a welding horn according to the weld schedule:
- the first pulse of ultrasonic vibration to workpieces;
- and
- after a cooling period, the second pulse of ultrasonic vibration to the workpieces.
22 more elements
Dependencies are inferred from the claim text.