Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.

An off-axis prepreg material manufacturing machine may include a robot configured to position a prepreg piece adjacent to an end of a prepreg layer. The machine may additionally include an alignment system configured to sense a position of the prepreg piece relative to the prepreg layer and generate a position signal representative thereof. The machine may also include a controller configured to receive the position signal and cause the robot to adjust the position of the prepreg piece such that an end edge of the prepreg piece and an end edge of the prepreg layer are in substantially abutting contact.

The invention relates to a hand-guided device (10) for setting a setting element (12) in a component. The device comprises a handle (14) for holding the device, a carriage (34), which can be moved in relation to the handle and which bears a rotatably supported drive shaft (46), at one end of which a holder for the setting element is formed, a force accumulator (44), which is arranged between the handle and the carriage and which serves to store a defined advancing force, with which the force limiter can be loaded by means of a relative motion between the handle and the carriage, and a force limiter (64) for limiting the advancing force stored in the force accumulator. The force accumulator is designed to apply the stored advancing force to the setting element by means of the carriage. The invention further relates to a method for manually setting a setting element by means of said device.

A system for in-line controlling of the ultrasonic welding of plastic components of an electronic cigarette, in which plastic components are welded to one another at a welding zone to define a welded group; the plastic components are such that the welded group has an air passage duct having a first open end and a second open end. The system includes: a chamber for receiving the welded group; a closure for closing the first open end; air supply for supplying air into the chamber. The system further includes an air exit, connecting the welding zone with the outside of the chamber; a continuous pressure control and adjustment for continuously controlling and regulating the air pressure that enters the air passage duct to keep a fixed air pressure; an air passage nozzle having a predetermined cross section, position between the continuous pressure control and adjustment and the second open end; and a pressure sensor for detecting the air back pressure generated in the chamber after the introduction of air into the air passage duct.

An ultrasonic welding system includes a movable ultrasonic welding stack for applying vibrational energy to a workpiece. A motion control system controls the motion of the ultrasonic welding stack and one or more sensors sense a control variable and output a corresponding control signal. A controller provides control inputs, based on the control signal, to the motion control system and causes, following initiation of a welding operation, an automatic change of speed of motion of the ultrasonic welding stack. The automatic change of the speed is a function of at least one control variable until the control variable reaches a predetermined value.

An apparatus for processing a workpiece with ultrasound comprises a base frame having a slide. A tool holder is connected to the slide via leaf springs, whereby a lifting device can move the tool holder relative to the slide.

Partly-finished products having side panel pieces are supplied intermittently to places between welding surfaces of a horn and a rotating anvil. Thus, the side pieces of the partly-finished products, are welded continuously to each other with a predetermined pattern. The welding surfaces of the anvil are provided over an entire circumference about a rotating shaft so that the interval between the welding surfaces of the anvil and the horns is maintained at an interval at which the respective side panel pieces are continuously weldable to each other with the predetermined pattern regardless of a rotating position of the anvil.

An ultrasonic welding system includes a motion control system that is coupled to and that causes controlled movement of an ultrasonic welding stack, in accordance with control inputs that are based on one or more control signals that are received from one or more sensors. The motion control system initiates a welding operation, subsequent to which an initial motion delay occurs until a predetermined condition is satisfied. Subsequently, in response to the predetermined condition being satisfied, the ultrasonic welding stack is caused to move in accordance with a weld profile. Subsequently, in response to an occurrence of a predetermined delay initiating condition, the ultrasonic welding stack is caused to stop motion and to maintain a stationary position. Subsequently, in response to an occurrence of a predetermined delay terminating condition, motion of the ultrasonic welding stack is resumed in accordance with the weld profile.

An ultrasonic welding system includes a motion control system that is coupled to and that causes controlled movement of an ultrasonic welding stack, in accordance with control inputs that are based on one or more control signals that are received from one or more sensors. The motion control system initiates a welding operation, subsequent to which an initial motion delay occurs until a predetermined condition is satisfied. Subsequently, in response to the predetermined condition being satisfied, the ultrasonic welding stack is caused to move in accordance with a weld profile. Subsequently, in response to an occurrence of a predetermined delay initiating condition, the ultrasonic welding stack is caused to stop motion and to maintain a stationary position. Subsequently, in response to an occurrence of a predetermined delay terminating condition, motion of the ultrasonic welding stack is resumed in accordance with the weld profile.

An ultrasonic welding system includes a motion control system that is coupled to and that causes controlled movement of an ultrasonic welding stack, in accordance with control inputs that are based on one or more control signals that are received from one or more sensors. The motion control system initiates a welding operation, subsequent to which an initial motion delay occurs until a predetermined condition is satisfied. Subsequently, in response to the predetermined condition being satisfied, the ultrasonic welding stack is caused to move in accordance with a weld profile. Subsequently, in response to an occurrence of a predetermined delay initiating condition, the ultrasonic welding stack is caused to stop motion and to maintain a stationary position. Subsequently, in response to an occurrence of a predetermined delay terminating condition, motion of the ultrasonic welding stack is resumed in accordance with the weld profile.