Ultrasonic welding device and ultrasonic welding method for controlling continuous ultrasonic welding processes

An ultrasonic processing method of an ultrasonic processing device, comprising:

• an ultrasonic generator, a converter and at least one sonotrode with an oppositely arranged counter tool, which are spaced from each other by a gap, wherein the counter tool is arranged rotatably and comprises an uneven circumferential surface having at least one detectable contour, a controlling/regulating module integrated in a signal processing of the ultrasonic generator so that with respect to the ultrasonic generator a plurality of generator data is processable in the ultrasonic generator, wherein the ultrasonic processing method comprises the following steps:
• a. determining an angular speed (speed I) of the rotatably arranged counter tool and transmitting the determined angular speed to a gap regulator and/or an amplitude regulator,
• b. detecting (step II) at least one data set of the plurality of generator data over a plurality of revolutions of the counter tool,
• c. evaluating timely periodically occurring patterns in at least one data set of the plurality of generator data plotted against the time based on a system time of the controlling/regulating module so that the angular speed of the counter tool is determinable without external sensor, and
• d. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the gap regulator and specifying a position reference value POSsoll of the sonotrode with respect to the counter tool and/or
• e. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the amplitude regulator and specifying an amplitude reference value in the ultrasonic generator for adjusting the power reference value Psoll of the ultrasonic generator.

Ultrasonic processing method of an ultrasonic processing device, comprising:

• an ultrasonic generator, a converter and at least one sonotrode with an oppositely arranged counter tool, which are spaced from each other by a gap, wherein the sonotrode or the counter tool is arranged rotatably and comprises an even or an uneven circumferential surface, a controlling/regulating module arranged in the ultrasonic generator and integrated in a signal processing of the ultrasonic generator so that with respect to the ultrasonic generator a plurality of generator data is processible in the ultrasonic generator, wherein the ultrasonic processing method comprises the following steps:
• a. determining an angular speed (step I) of the rotatably arranged counter tool or the rotatably arranged sonotrode and transmitting the determined angular speed to a gap regulator and/or an amplitude regulator,
• b. detecting (step II) at least one data set of the plurality of generator data,
• c. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the gap regulator and specifying a position reference value POSsoll of the sonotrode with respect to the counter tool, and/or
• d. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the amplitude regulator and specifying an amplitude reference value Asoll in the ultrasonic generator for adjusting the power reference value Psoll of the ultrasonic generator,
• wherein the ultrasonic processing method comprises the further steps:
• e. adjusting a fixed gap between the sonotrode and the counter tool, wherein no position sensor with actuator is required, and
• f. regulating the power reference value Psoll of the ultrasonic generator by adjusting the amplitude reference value Asoll of the sonotrode.

Ultrasonic processing method of an ultrasonic processing device, comprising:

• an ultrasonic generator, a converter and at least one sonotrode with an oppositely arranged counter tool, which are spaced from each other by a gap, wherein the sonotrode or the counter tool is arranged rotatably and comprises an even or an uneven circumferential surface, a controlling/regulating module arranged in the ultrasonic generator and integrated in a signal processing of the ultrasonic generator so that with respect to the ultrasonic generator a plurality of generator data is processible in the ultrasonic generator, wherein the ultrasonic processing method comprises the following steps:
• a. determining an angular speed (step I) of the rotatably arranged counter tool or the rotatably arranged sonotrode and transmitting the determined angular speed to a gap regulator and/or an amplitude regulator,
• b. detecting (step II) at least one data set of the plurality of generator data,
• c. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the gap regulator and specifying a position reference value POSsoll of the sonotrode with respect to the counter tool, and/or
• d. comparing a power actual value Pist with a power reference value Psoll of the ultrasonic generator in the amplitude regulator and specifying an amplitude reference value Asoll in the ultrasonic generator for adjusting the power reference value Psoll of the ultrasonic generator,
• wherein the ultrasonic processing method comprises the further step:
• e. adjusting the power reference value Psoll of the ultrasonic generator by means of the gap regulator and the amplitude regulator in combination, wherein the power reference value Psoll of the ultrasonic generator is regulatable by means of an active gap adjustment in combination with an amplitude adjustment of the sonotrode.