A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

A feedback control system for use with ultrasonic welding. A weld energy set point and/or a reference power curve are used by a controller to provide a power supply voltage set point and a power supply frequency set point for the power that is to be drawn by an ultrasonic weld generator. Information regarding the actual voltage and/or frequency of the drawn electrical power, and/or the frequency and magnitude of an ultrasonic wave transmitted from the generator to an applicator tool used to weld an object can be utilized by an estimator to estimate the weld energy dissipated at the weld site and/or generate a power curve for the welding operation. Using information from the estimator, the controller can determine adjustments for variables for the current and/or future welding operations. Further, welding may not commence until a clamping force exerted on the object satisfies a clamping force set point.

The present invention relates to a method for ultrasonic treatment of a plastic material, comprising the steps of: positioning the plastic material between a sonotrode and a counter-tool, bringing the sonotrode excited by means of an ultrasonic oscillation into contact with the plastic material during a welding phase, moving the sonotrode and the counter-tool towards each other during a holding phase, in which neither the sonotrode nor the counter-tool are excited with an ultrasonic oscillation so that a force F is applied onto the plastic material. In order to reduce treatment times, wherein at the same time the quality of the welding process is not impaired but is even to be improved, it is proposed according to the invention that the force F is varied during the holding phase.

The present invention concerns a method of detecting the making or breaking of contact of a sonotrode (4) which is caused to vibrate with a frequency f and a vibration amplitude A.sub.0 with a counterpart element (5). To provide a method with which contact-making or breaking of a sonotrode with a counterpart element can be particularly quickly and inexpensively detected it is proposed according to the invention that the method has the following steps: a) recording a time configuration of the vibration amplitude A.sub.0 (1) during a first measurement time interval ΔT, and b) determining from the time configuration of the vibration amplitude A.sub.0 (1) whether making or breaking of contact occurred within the measurement time interval ΔT.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

An application unit (13) comprises a rotation unit (26) and a support unit (27). The rotation unit (26) comprises a nozzle unit (28), a nozzle support part (29), a body base (30), a first supply part (31), a second supply part (32), a third supply part (33), a valve (34), and a motor (35). The nozzle support part (29) rotatably supports the nozzle unit (28) such that the central axis of the nozzle unit (28) is inclined with respect to the rotation axis of the rotation unit (26).

An ultrasonic processing method and an ultrasonic processing device may include a controlling/regulating module, preferably a digital controlling/regulating module, which is integrated into a signal processing of the ultrasonic generator so that a plurality of generator data with respect to the ultrasonic generator are processible in the ultrasonic generator. At this, a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via a gap regulator in the controlling/regulating module to specify a position reference value POS.sub.soll of the sonotrode relative to the roll for adjustment of the power reference value P.sub.soll of the ultrasonic generator, and/or a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via an amplitude regulator in the controlling/regulating module to specify an amplitude reference value A.sub.soll to the ultrasonic generator for adjustment of the power reference value P.sub.soll.

The present invention provides, in various embodiments, a rotary-type machine (M) for continuously sealing individual foil bags (B) by way of ultrasonic welding between an anvil (6) and a sonotrode (5) in at least one welding station (S) of a carousel (1), where each foil bag (B) can be positioned by way of holders (11). In some embodiments, the rotary-type machine (M) comprises at least one welding station (S) composed of a sonotrode (5) being located stationary at least relative to the direction of circulation (8) and anvils (6) which with intermediate spacings (7) rotate past said sonotrode (5) successively in the direction of circulation (8) of the carousel (1). According to the invention, the foil bags (B) are sealed at the stationary sonotrode (5) when the anvils (6) equipped with the foil bags (B) are rotated past.