Actively controlled vibration welding system and method

A method comprising:

• positioning an active material element with respect to a welding anvil assembly;
• connecting the anvil assembly to a support member;
• transmitting a first input signal from a controller to a converter to thereby vibrate a welding horn in a first direction, and to thereby form a weld on a work piece;
• transmitting a second input signal from the controller to the active material element;
• and
• generating a calibrated output within the anvil assembly via the active material element in response to the second input signal to actively control vibration of the anvil assembly in a second direction that is different from the first direction.

A vibration welding system comprising:

• a controller that selectively generates a first input signal and a second input signal;
• a welding horn in electrical communication with the controller, wherein the horn is configured to vibrate in a first direction in response to the first input signal to thereby form a weld with respect to a work piece;
• an anvil assembly having an anvil body and a back plate, wherein the anvil body and the back plate are mounted to each other and to a support member;
• a sensor positioned with respect to the anvil assembly in electrical communication with the controller, and configured to measure a vibration of the anvil assembly in a second direction;
• and
• a piezoelectric stack positioned between the anvil body and the back plate, wherein:
• the controller is configured to generate the second input signal as a function of the measured vibration;
• and
• the piezoelectric stack is configured to apply a calibrated displacement or strain to the anvil assembly in response to the second input signal to thereby actively control vibration of the horn in a second direction that is different from the first direction.