Systems and methods for adaptive process control using a target kinematics profile in welding together multiple polymeric workpieces

摘要

An ultrasonic welding system, for welding together two workpieces wherein at least one of the workpieces includes a polymeric composite, comprising an energy applicator positioned along an action axis so that, in operation, ultrasonic vibrations transmitted from the energy applicator during a welding routine, are transmitted to the workpieces generally at and/or adjacent the axis. The system also includes a primary, course-control, actuator positioned along action axis so that a first load, output by the primary actuator, acts along the system action axis. The system further comprises a secondary, fine-control, actuator positioned along the system action axis so that a second load output, by the secondary actuator, acts along the axis. And the system comprises a controller for providing first command signals and second command signals to the primary actuator and second actuator to control them to effect loads on the workpieces, during the welding routine and along the axis.

主权项

1. An ultrasonic welding system, for welding together two workpieces, comprising:
an energy applicator positioned along a system action axis so that, in operation, ultrasonic vibrations transmitted from the energy applicator during a welding routine are transmitted to the workpieces generally at and/or adjacent the system action axis; a primary, course-control, actuator positioned along the system action axis so that a first, course-type, load output by the primary, course-control, actuator acts along the system action axis; a secondary, fine-control, actuator positioned along the system action axis so that a second, fine-type, load output by the secondary, fine-control, actuator acts along the system action axis; and a controller:
in operative communication with the primary, course-control, actuator and with the secondary, fine-control, actuator;comprising data including an energy-applicator kinematic profile having target kinematic data points in association with time or output energy for the welding routine; andconfigured to generate, based on the energy-applicator kinematic profile, a primary, course-type, command signal and a secondary, fine-type, command signal to control the primary, course-control, actuator and the secondary, fine-control, actuator, respectively, to effect loads on the workpieces along the system action axis during the welding routine.