Dual ultrasonic welder

A dual ultrasonic welder unit for coupling to a robot, comprising:

• a. a mounting bracket coupled to an end of an arm of a robot, the mounting bracket including first base member aligned in a first plane, a second top member aligned in a second plane orthogonal to the first plane and being adapted to be coupled to the end of the robot, a first extension member aligned in a third plane orthogonal to the first plane and orthogonal to the second plane, the first extension member including a first passage, and a second extension member aligned in a fourth plane parallel to the second plane and orthogonal to the first plane, the second extension member adapted for having a second ultrasonic welder fixedly coupled thereto;
• b. a mounting bar assembly including a first portion coupled to the mounting bracket and a second portion for coupling to a first ultrasonic welder;
• c. a first ultrasonic welder coupled to the second portion of the mounting bar assembly and adapted to be independently of the robot adjustable in at least two directions with respect to the mounting bracket;
• d. a second ultrasonic welding gun fixedly coupled to the mounting bracket and positioned relative to the first ultrasonic welder;
• e. an adjuster having a first portion coupled to the first ultrasonic welding gun and a second portion coupled to the second ultrasonic welding gun, the adjuster for adjusting the distance between the first and second ultrasonic welding guns in at least one direction.

A welder comprising:

• a. a mounting bar assembly adapted to be mounted to an end of an arm of a robot, the mounting bar assembly attached with respect to an end of an arm of the robot along one side of the mounting bar assembly, the mounting bar assembly further having an attachment bar mounted to another side of the mounting bar assembly, the attachment bar having a slide guide rail mounted to the attachment bar for its longitudinal extent;
• b. an extended mounting bracket having a complementary key way groove slidably attached to the slide guide rail of the attachment bar enabling sliding movement of the extended mounting bracket along the slide guide rail of the attachment bar;
• c. a top end bracket having a bottom surface and an extended portion securely fixed to the mounting bar assembly for movement therewith;
• d. a first ultrasonic welder having an ultrasonic transducer housing mounted to the bottom surface of the top end bracket whereby the first ultrasonic welder is limited to the same directional movement as the end of the arm of the robot;
• e. a second ultrasonic welding gun having an ultrasonic transducer housing, the second ultrasonic welding gun fixedly coupled to the extended mounting bracket;
• f. a ball screw assembly mounted to the mounting bar assembly, the ball screw assembly having a ball screw threaded shaft extending in a direction toward the extended mounting bracket, the extended mounting bracket having a ball nut integral therewith for receiving the ball screw threaded shaft whereby when the ball screw assembly is activated to rotate the ball screw threaded shaft within the ball nut, the second ultrasonic welding gun attached to the extended mounting bracket is moved in a direction with respect to the first ultrasonic welder which is substantially orthogonal with respect to a direction of ultrasonic welding.