Claims
- 1. A method of vibration welding a workpiece, the method comprising the steps of:
fastening a first workpiece portion to a fixed position; fastening a second workpiece portion to a reciprocating member, the reciprocating member having a relaxed position defining a zero point; energizing a first single winding magnet with direct current power to create a magnetic field, whereby the reciprocating member is urged in a first direction by the magnetic field; sensing a location of the reciprocating member with respect to the zero point, the reciprocating member having a maximum displacement from the zero point defining an amplitude; and energizing a second single winding magnet with direct current power when the reciprocating member has crossed the zero point while moving towards the first single winding magnet.
- 2. The method of claim 1, further comprising the step predicting the amplitude of the flexure member by trajectory modeling.
- 3. The method of claim 2, further comprising the step of controllably adjusting the energization of one or both of the first and the second single winding magnets to affect the amplitude of the reciprocating member.
- 4. A method of reducing tool over-travel at a weld part interface in a vibration welding operation, the method comprising the steps of:
defining an amplitude for a reciprocating member based on a reference point; sensing a location of the reciprocating member with respect to the reference point; predicting the amplitude of the reciprocating member; and adjusting power input to a single winding magnet to alter the amplitude of the reciprocating member.
- 5. The method of claim 4, further comprising the step of calculating the velocity of the reciprocating member.
- 6. The method of claim 4, further comprising the steps of:
fastening a first workpiece portion to a fixed position; and fastening a second workpiece portion to a reciprocating member, the reciprocating member having a relaxed position defining a zero point.
- 7. The method of claim 4, further comprising the step of relaying the location to a controller.
- 8. A method for dynamically controlling a vibration welding operation, the method comprising the steps of:
sensing a tool position for a vibration welding tool; determining if the tool position changed with respect to a stored tool position; determining a tool velocity; determining a predicted tool position; and outputting a control command to an amplifier based upon the predicted tool position.
- 9. The method of claim 8, further comprising the step of centering the tool.
- 10. The method of claim 8, further comprising the step of defining an amplitude for the tool based upon the tool velocity.
- 11. The method of claim 8, further comprising the step of updating t he stored tool position to be equal to the tool position.
- 12. The method of claim 11, further comprising the step of inputting the amplitude and an amplitude setpoint value into a proportional integral derivative algorithm.
- 13. A method for monitoring a vibration welding operation, the method comprising:
a step for sensing a tool position for a vibration welding tool; a step for determining if the tool position changed with respect to a stored tool position; a step for determining a tool velocity; a step for calculating a predicted tool position; and a step for outputting a control command.
- 14. The method of claim 13, further comprising a step for updating the stored tool position.
- 15. The method of claim 14, further comprising a step for inputting the amplitude and an amplitude setpoint value into a proportional integral derivative algorithm.
- 16. An apparatus for vibration welding comprising:
a frame; a flexure array operably connected to the frame, the flexure array having a first end and a second end; a first magnet assembly disposed on the frame, the first magnet assembly comprising a single pole electromagnet; a second magnet assembly disposed on the frame, the second magnet assembly comprising a single pole electromagnet; a digital controller operably connected to the first magnet assembly and the second magnet assembly; a first direct current amplifier electrically connected to the first magnet assembly and the digital controller; and a second direct current amplifier electrically connected to the second magnet assembly and the digital controller.
- 17. The apparatus of claim 16, further comprising:
a first clamp operably connected to the flexure array; and a second clamp rigidly disposed on a table assembly.
- 18. The apparatus of claim 16, further comprising:
a target disposed on the flexure assembly; and a position sensing device provided to the frame and operably connected to the digital controller, wherein the position sensing device determines the position of the flexure array relative to the target.
- 19. The apparatus of claim 18, wherein the position sensing device is an analog sensor.
- 20. The apparatus of claim 18, wherein the position sensing device is a digital sensor.
- 21. The apparatus of claim 18, wherein the digital controller predicts a tool position based upon the position relayed by the position sensing device.
- 22. The apparatus of claim 21, wherein the digital controller selectively energizes one of the first magnet assembly or second magnet assembly based upon the predicted tool position.
- 23. A vibration welding apparatus comprising:
a frame; a flexure assembly operably connected to the frame, the flexure assembly comprising:
a plurality of flexure members, each flexure member having a top surface and a bottom surface, the flexure members rigidly fastened to the frame by way of a frame connection member fastened to the top surface and to the frame; a base plate fastened to the bottom surface of the flexure members; a force transfer member having a first end and a second end, the force transfer member rigidly disposed on the base plate;
a first direct current electromagnet assembly provided to the frame and in operable communication with the first end of the force transfer member; and a second direct current electromagnet assembly provided to the frame and in operable communication with the second end of the force transfer member, wherein the force transfer member is linearly oscillatable between the first electromagnet assembly and the second electromagnet assembly, thereby defining an amplitude; a position sensor provided to the flexure assembly for determining the position of the force transfer member relative to a zero point, the zero point defined to be the position of the force transfer member at rest; and a controller operably connected to the first electromagnet assembly, the second electromagnet assembly and the position sensor, the controller selectively controlling the energization of the first electromagnet assembly and second electromagnet assembly so that one of the second electromagnet assembly is energized when the force transfer member passes the zero point while traveling towards the first electromagnet assembly.
- 24. The apparatus of claim 23, wherein the controller predicts the position of the force transfer member by performing a proportional integral derivative calculation.
- 25. The apparatus of claim 23, further comprising a graphical user interface operably connected to the controller, the interface for displaying system information.
- 26. The apparatus of claim 23, further comprising a transverse brace fastened to each of the frame connection members.
- 27. A vibration welding apparatus for joining a first workpiece portion to a second workpiece portion, the apparatus comprising:
a frame; means for linearly oscillating the workpiece first portion relative to the workpiece second portion, said oscillating means operably provided to the frame; means for generating a first magnetic field, means for generating a second magnetic field; and means for dynamically controlling the generation of the first magnetic field generation means and the second magnetic field generation means.
- 28. The welding apparatus of claim 29, further comprising means for securing the workpiece first portion to the oscillating means;
- 29. The welding apparatus of claim 29, further comprising means for pressing the workpiece second portion towards the workpiece first portion under pressure.
- 30. An apparatus for vibration welding comprising:
a frame; a flexure array operably connected to the frame, the flexure array having a first end and a second end; a first magnet assembly disposed on the frame, the first magnet assembly comprising a single pole electromagnet; a second magnet assembly disposed on the frame, the second magnet assembly comprising a single pole electromagnet; a digital controller operably connected to the first magnet assembly and the second magnet assembly, the digital controller configured to perform a linear vibration welding operation without autotuning; a first direct current amplifier electrically connected to the first magnet assembly and the digital controller; and a second direct current amplifier electrically connected to the second magnet assembly and the digital controller.
Parent Case Info
[0001] This application claims the benefit of priority to U.S. provisional application No. 60/277,755, filed on Mar. 21, 2001 and U.S. provisional application No. 60/277,757, filed on Mar. 21, 2001, both incorporated herein by reference in their entirety.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60277755 |
Mar 2001 |
US |
|
60277757 |
Mar 2001 |
US |