EP3676043A1

EP3676043A1 - Method for welding electrical conductors by means of ultrasound and ultrasonic metal welding device

Info

Publication number: EP3676043A1
Application number: EP18762053.9A
Authority: EP
Inventors: Sebastian RÜHL; Peter Wagner; Udo Wagenbach; Heiko Strobel
Original assignee: Schunk Sonosystems GmbH
Current assignee: Schunk Sonosystems GmbH
Priority date: 2017-08-29
Filing date: 2018-08-27
Publication date: 2020-07-08
Also published as: KR102600716B1; US11458562B2; JP2020532428A; KR20200049790A; US20200171597A1; US11839928B2; MX2020001371A; MA50026A; US20220402069A1; WO2019042909A1; JP7244982B2; DE102017119809A1; CN111344100A

Abstract

The invention relates to an ultrasonic metal welding device and to a method for welding electrical conductors having a clearance space that is adjustable at least in height, which clearance space is delimited in opposite sides by a portion of a sonotrode as the first delimiting surface and by at least one portion of a counter electrode (156) as the second delimiting surface, the counter electrode and the sonotrode being adjusted relative to one another for welding. The type of counter electrode used is one that comprises portions (152, 154) of geometrically different working surfaces or consists of at least two portions that are adjustable relative to one another.

Description

description

METHOD FOR WELDING ELECTRIC LADDERS BY MEANS OF ULTRASOUND AND ULTRASONIC METAL WELDING DEVICE

The invention relates to a method for welding and / or deforming electrical conductors and / or surrounding envelopes, such as tubular cable lug, with an at least in height, adjustable compression space, in opposite sides of a portion of a sonotrode as a first boundary surface and of at least a portion of a counter electrode is limited as a second boundary surface, wherein for welding the counter electrode and the sonotrode are adjusted relative to each other with simultaneous pressurization of the electrical conductors and energized sonotrode. Preferably, the compression space is adjustable in height and width. Therein, the compression space in opposite sides of a portion of a sonotrode as a first boundary surface and of at least a portion of a counter electrode as a second boundary surface and in the remaining sides of one of a portion of a side slider is limited as a third boundary surface and a portion of a boundary element as a fourth boundary surface , Also, the invention relates to an ultrasonic metal welding device with an at least in height, preferably in height and width, adjustable Compacting lines formed in opposite sides of a portion of a sonotrode as a first boundary surface and at least a portion of a counter electrode as a second boundary surface and in height and width adjustable compression space in the remaining sides of one of a portion of a side slider as a third boundary surface and a portion of a limiting element is limited as a fourth boundary surface, wherein for closing or opening of the compression space, the counter electrode is adjustable relative to the sonotrode. The invention also relates to an ultrasonic welding tool.

For manufacturing harnesses, it is common in the automotive industry for strands to be tied into nodes by ultrasonic welding. It must be ensured that a given number of strands are completely welded into a node in order to transmit signals or to conduct electricity. For verification, the welding process itself can be used, i. H. that a characteristic parameter of a height and width adjustable compression space is representative of the number of welded strands, so that a process control is ensured. However, this is basically only possible if each of the strands to be welded has a minimum cross-section.

Due to the further development of the electronics used, it is possible strands consisting of individual wires or wires, with cross sections of z. B. 0.13 mm ² , over which sufficient signals can be passed or current can flow. If corresponding strands are welded with strands of larger cross-section, then there is the risk that the strands of small cross-section get into interspaces between larger strands, so that ultimately the characteristic parameter of the compression space, such as height or width, determined after welding is no longer sufficiently meaningful, if indeed the predetermined number of strands are materially interconnected.

Ultrasonic welding devices with which corresponding nodes can be welded, z. DE 44 29 484 A1, EP 0 143 936 B1, DE 10 2005 004 899 A1 or DE 37 19 083 A1, which have adjustable in height and width compression spaces.

A likewise adjustable in height and width compression space is known from WO 95/10886 AI. However, in this Ulrraschdlschweißvorrichtung the compression chamber is set to a predetermined height-width ratio regardless of the cross section of the conductors to be welded

DE 10 2011 014 801 A1 discloses a method for welding conductors. A two-stage process is used. In a first step, a plurality of conductors are welded to a first node to then weld in a second step with other conductors or nodes.

DE-Z .: The Library of Technology, Volume 108: Ultrasonic metal welding, Verlag Moderne Industrie, 86895 Landsberg 1995, principles of ultrasonic welding can be found. In the document, the structure and function of an ultrasonic welding device for welding metal are explained in particular on pages 20 ff. The disclosure in this regard is expressly referred to, as well as to the other cited as prior art documents, as far as the adjustment of a compression chamber or the function of an ultrasonic welding device are concerned. In that regard, the content of the relevant documents is considered to be a disclosure of the present invention.

If, in addition to the welding of conductors such as strands, a mechanical fixing of the welded connection is to be achieved, different tools are usually used which extend and increase the cost of the manufacturing process.

Thus, DE 10 2008 045 751 A1 discloses a device and a method for Kompakti ersch white to connect an electrical line with an electrical connection contact. In addition, it is possible to connect the terminal contact with the line by means of an insulation crimp, which is produced with a separate crimping tool. In order to connect a line consisting of strands via a crimp connection to an electrical connection, according to US 2015/0060135 A1, the strands are welded end-to-end by means of ultrasonic welding, wherein a recess running in the longitudinal direction of the strands is formed, in which crimped plates are fixed.

It is also possible to stir welds in various ultrasonic welding devices.

The present invention has the object, a method of the type mentioned in such a way that a procedural simplification during welding and optionally deforming electrical conductors, in particular different cross-sections, can be achieved.

According to another aspect, the possibility should be given to expand the cross-sectional areas of an ultrasonic welding device for conductors to be welded, without any restrictions in the process monitoring.

Also, properties of nodes to be welded are to be optimized. Another aspect is to open up the possibility of additional measures to be welded to conductors to ensure a secure electrical and mechanical connection and possibly perform a mechanical inspection of welds. In order to solve one or more aspects, according to the invention, the method mentioned at the outset is developed essentially by using a counterelectrode which has sections of work surfaces which differ from one another geometrically or consists of at least two mutually adjustable sections. As a sonotrode, one can be used which, as in the prior art, has a working surface as a welding surface.

However, there is also the possibility that the sonotrode adjoin at least two contiguous or adjacent working surfaces with geometrically diverging welding surfaces or a welding surface as an inventive idea Work surface and a work surface with shaping or embossing function has. The anein other bounding or adjacent work surfaces are thus not to be confused with those which are arranged along the peripheral surface of a sonotrode and are aligned by rotating the sonotrode on the counter electrode. The respective desired working surface of the adjacent or adjacent work surfaces is selected by relative axial adjustment along the sonotrode longitudinal axis between sonotrode and counter electrode to the portion of the counter electrode, which is to be used in welding or in the molding or in the mechanical inspection of a welded joint.

In particular, it is provided that, depending on the electrical conductors to be welded, the section of the counterelectrode or the welding surface of the sonotrode or both the section of the anvil and the welding surface are selected.

In a further development, the invention provides that in a first welding operation with a first portion of the counter electrode electrical conductors are welded to form an intermediate node and that welded in a second welding operation, the intermediate node with at least one further conductor and / or another intermediate node to a node wherein the second welding operation uses a second portion of the counterelectrode deviating from the first portion and / or a welding surface different from that used in the first welding operation. In this case, with the position of the intermediate node unchanged, it can be welded to the further conductor and / or the further intermediate node using the second section of the counterelectrode.

Another proposal is characterized in that, in a first welding operation, first conductors are welded using a first portion of the counter electrode to an end or via node which is then welded and / or deformed using a second portion of the counter electrode deviating from the first portion. It is also possible that with a first portion of the counter electrode conductors are welded to a terminal node and with a second portion of the counter electrode conductor to a passage node. A working surface of the counter electrode may also be formed such that a crimping or cutting operation is performed.

A working surface of the counterelectrode can also be designed as a test element such as a test jaw in order to be able to check the mechanical strength of a welded joint. For this purpose, a defined test force is introduced into the welded connection between the work surface designed as a test element and the sonotrode serving as a counter element, which is so high that no damage occurs in the case of a perfect welded connection. If there is a faulty welded connection, detectable changes to the welded connection can be detected.

It should also be emphasized that, with the working surface of the sonotrode surrounding the final or shaping function, a notch can be embossed in an envelope surrounding a conductor, in particular running transversely as perpendicular to the sonotrode longitudinal axis.

According to the invention, it is possible to easily weld strands of smaller cross sections with strands of larger cross sections in one and the same ultrasonic welding device, even if the cross section of the strand has the smallest cross section relative to the total cross section of the node, in and of itself accurate process monitoring, in particular for determining the number the welded conductor is basically not possible or not mandatory.

It can be checked after welding the strands of different cross sections due to a characteristic parameter of the compression space, if the required number of strands are welded together.

Due to the fact that the sections of the counterelectrode - also called anvil - and / or the sonotrode can have different structures, the Possibility of welding both through and end knots in one and the same machine.

The sections of the counter electrode and optionally the sonotrode may have different profiles, in particular a finer and a coarser profile, so that strands of small and strands of large cross sections are equally error-free and reproducible to weld, without the need for replacement of tools or different ultrasonic welding devices used must arrive. To ensure process monitoring, the cross section of the smallest strand should not be less than, for example, 7% of the cross section of the node. If, for example, strands of a cross section of 0.13 mm ^{2 are} used, according to a corresponding rule, the total cross section should not be greater than about 1.9 mm ² . According to the invention, a plurality of strands of small cross section, eg three strands each having a cross section of 0.13 mm ² , can now be welded to form an intermediate node, so that consequently the intermediate node is welded with further strands to form a knot of a cross section of approximately 5.6 mm ² can be used without any disadvantages in process monitoring. For welding the strands of small cross section, a portion of the counter electrode, which may also be called anvil, is then used with a finer structure. When welded to the strands of larger cross section, a section with a coarser structure is then used.

To bring the different sections used, according to the teaching of the invention of the mutually adjustable sections of the one can limit the compression space, which has the desired structure, ie profiling. It is also possible to adjust the respective section in a circumference parallel to the working surface of the sonotrodes, that a compression space of desired cross-section is available, which is limited when welding nodes from four sides.

The mutually adjustable sections can be arranged side by side or one above the other, wherein in a side-by-side arrangement the advantage is given that the sections can be assigned to different areas of the sonotrode which each form a welding area.

Since the sections can have symmetrical and asymmetrical profiles, there is the advantage that, depending on the profile used, end nodes or through-ties of the same quality can be welded in one and the same machine. An asymmetric profile for end nodes and a symmetric profile for through nodes can be used. Asymmetrical means that on the input side of the compression space of the working surface of the counter electrode is an arcuate elevation extending in the section, which extends in the direction of the sonotrode. Then follow up elevations and depressions. In the case of a symmetrical profile, corresponding arcuate elevations extend from the working surface of the anvil both on the compression chamber inlet side and on the outlet side. Of course, it is also possible to weld end and through nodes with symmetrical profile.

In particular, even if end nodes are to be welded, a stepped sonotrode can be used according to a suggestion to be emphasized, so that the step itself serves as a stop for the ends of the strands to be welded. The sonotrode thus has two welding zones separated by the step, one of which may be designed for the welding of end nodes and the other for the welding for passing nodes. Each of the areas is associated with one of the mutually adjustable sections of the counter electrode.

A so-called double welding can be carried out without any problem, wherein a first node with a cross section of, for example, 3 × 4 mm ^{2 is} welded, which serves as an intermediate node, in order then to weld with it further strands or another intermediate node.

At least one working surface of the counterelectrode can have a shaping geometry in order, for example, to weld leads around. However, it is also possible to design a working surface in such a geometric way that a crimping or cutting function can be achieved.

Accordingly, the sonotrode may have a portion adjacent to the welding surface, e.g. for mechanical shaping or embossing of a conductor surrounding envelope, such as pipe cable lug used. For this purpose, in particular, a combing or bead-starting section of the sonotrode is provided, which runs adjacent to the welding surface, in order, during the welding of strands, at the same time in an envelope, e.g. in a cable lug to form a recess, through which a high mechanical strength of the connection between the envelope, such as the cable lug, and the electrical conductors is achieved. In this case, the recess or notch-generating region, that is to say, the comb-shaped or bead-like section, which has in particular an arcuate shape, should run perpendicular to the longitudinal axis of the sonotrode which can be excited in the longitudinal axis direction, without this being a mandatory feature. Rather, a parallel course could also be selected depending on the field of application.

Similarly, a torsion sonotrode can be used. Welding also takes place with the comb or bead-like section.

An ultrasonic metal welding device of the type described above is characterized in particular in that the counterelectrode has sections with geometrically divergent working surfaces or consists of at least two mutually adjustable sections and the sonotrode has at least one working surface as welding surface or

in that the counterelectrode has sections with work surfaces which differ from one another geometrically or consists of at least two mutually adjustable sections and / or the sonotrode has at least two adjacent or adjacent working surfaces with geometrically divergent welding surfaces or a working surface as welding surface and a working surface with complementary shaping or embossing Function has. There is also the possibility that one of the working surfaces of the counter electrode as a further function exerts, for example, a crimping or cutting function or a function for testing the strength of a welded connection. For this purpose, from the work surface z. B. emanating a tapered projection, which acts on the welded joint with a predetermined test force.

In a further development, the invention provides that the counterelectrode has at least two sections which can be displaced parallel to one another and parallel to the working surface of the sonotrode and which can optionally be assigned to the working surface or one of the working surfaces of the sonotrode. In the case of a peripherally sealed compression space, this is limited by the portion of the counter electrode.

In this case, the two sections can be arranged above or next to one another. Also, the sections may be telescopically adjustable.

The adjustable sections themselves should be operated via separate drive means such as cylinders. In particular, it is provided that the work surfaces have at least the counter electrode diverging profiles, with respect to a perpendicular to the respective working surface and this center in the longitudinal direction of the compression chamber intersecting plane preferably one of the profiles symmetrical and the other is asymmetrical or both symmetrical or have asymmetrical, but have different structuring.

Self-inventively on its own, if necessary in combination with previously described features, and protection-enhancing is the possibility that the sonotrode has two Schwedßflächen extending in height spaced apart and extending parallel planes. In the case of a longitudinal oscillator as a sonotrode, which is set in vibration along its longitudinal axis, the welding surfaces consequently run side by side.

In order to additionally exercise shaping or shaping functions, it is provided that one of the working surfaces of the sonotrode has a comb or bead-like geometry, whose Ers extension is parallel or perpendicular to the sonotrode longitudinal axis. This applies in particular to the welding and forming of tubular cable lugs.

An ultrasonic welding tool in the form of a sonotrode is characterized in particular by the fact that the sonotrode has two welding surfaces which extend in height-spaced mutually parallel planes and adjoin one another.

In order to achieve further functions, provision is made in particular for one of the work surfaces to have a comb-like or bead-like geometry whose extension runs parallel or perpendicular to the longitudinal axis of the sonotrode.

The invention also relates to a method of the type mentioned, in which for welding and / or deformation of electrical conductors, the counter electrode has a single working surface and the sonotrode at least two working surfaces, as has been previously explained.

Thus, the invention is also characterized by a method for welding and / or deformation of electrical conductors and / or surrounding sheaths, such as pipe cable lug, with a at least in height, preferably in height and width, adjustable compression space in opposite sides of a Section of a sonotrode as a first boundary surface and of at least a portion of a counter electrode as a second boundary surface and preferably in the remaining sides of one of a portion of a side slider as a third boundary surface and a portion of a limiting element is limited as a fourth boundary surface, wherein for welding the counter electrode and the sonotrode be adjusted relative to each other, being used as a sonotrode, which at least two adjacent or adjacent work surfaces with geometrically divergent welding surfaces or at least one welding surface as Arbe has its surface and a work surface with embossing or shaping function. For more details, advantages and features of the invention will become apparent not only from the claims, the features to be taken these features - alone and / or in combination - but also from the following description of the drawing to be taken preferred exemplary embodiments. Show it:

1 is a schematic diagram of an ultrasonic welding machine,

Fig. 2 shows a detail of an ultrasonic welding device with open

Compression chamber,

3 with the ultrasonic Schwdßvorrichtung according to FIG. 2 with a first portion of a counter electrode with closed compression space,

4 shows the ultrasonic welding device according to FIG. 2 with a second section of the counterelectrode with the compression space closed, FIG. 5 shows a schematic illustration of a second exemplary embodiment of a

Counter electrode,

6 shows a schematic diagram of a third embodiment of a counterelectrode, FIGS. 7a-7c shows a schematic diagram of a fourth embodiment of a counterelectrode,

8 is a schematic diagram of a second Ausfuhrungsfbrm a sonotrode,

9 shows a third embodiment of a sonotrode,

10 shows a fourth embodiment of a sonotrode,

11a-11d strands of different cross-sections and junctions of these and FIGS. 12a, 12b strands welded to an end node.

In Fig. 1, a plant is shown purely in principle, are welded to the strands by means of ultrasound. The arrangement comprises an ultrasonic metal welding device or machine 110, which in the usual way a converter 112, if necessary. A booster 114th and a sonotrode 116. The sonotrode 116 or a working surface of these are associated with a counter electrode 118, a spotting plate 119 and a side slide 120, as can be seen in DE 37 19 083 C1 or WO 95/10866 AI or DE 44 29 684 A1, on the Revelation is expressly referenced. The sonotrode 116 or its working or welding surface displaceable in the direction of its longitudinal axis, the counterelectrode 118, a limiting element 119 which is adjustable as a unit with the counterelectrode 118 and to which the counterelectrode 118 can be displaced in the direction of the side slide 120, as well as the side shifter 120 define a compression space which can be adjusted in cross-section and which is provided with the reference numeral 42 in FIGS. 2 to 4 and is inserted into the strands to be welded.

The converter 112 is connected via a line 122 to a generator 124, which in turn leads via a line 126 to a PC 128. This is used to control or regulate the welding process. Furthermore, welding parameters or cross section or width of the strands can be entered. Also stored values can be retrieved.

Furthermore, transducers, not shown, may be provided, determined via the height and / or width of the compression space before or after carrying out a weld. The values allow conclusions about the number of compacted and welded strands. Thus, a process control can be performed. Instead of one or more transducers to determine the height and width and thus the cross-section of the compression space and other sensors can be used or other measures are used to draw in a known manner conclusions about the number of welded strands can.

To z. B. in wiring harnesses strands of different cross-sections process reliable and verifiable in relation to the number verifiable, is provided in consideration of the illustration in Fig. 11 that initially strands 12, 14, 16, in their stripped areas 18, 20, 22 with stripped areas 24, 26 of other strands 28, 30 of larger cross-section to z. B. an end or transit node 32 are to be materially connected, initially welded together. This is shown by a comparison of FIGS. 11a and 11b. Thus, first the bare ends 18, 20, 22 become a first Node 34 or intermediate node welded, which runs a considerable distance from the insulation 36, 38, 40 of the strands 12, 14, 16 in order to avoid mechanical stresses that could possibly lead to damage of the wires of the individual strands 18, 20, 22. The strands 12, 14, 16, ie their respective wires or wires in the bare ends 18, 20, 22 may, for. B. each having a cross section of 0.13 mm ² , without thereby limiting the teaching of the invention takes place. Would relevant strands directly, ie bypassing the intermediate node 34 with the strands 28, 30 larger cross section, z. B. cross-sections of 0.35 mm ² , welded, it could not be determined reproducibly from measured values of the height and / or width of the compression chamber or any other characteristic parameter of the compression chamber, whether for proper interconnection z. B. a harness required number of strands of different cross-sections are welded together. This disadvantage is circumvented in that initially the intermediate node 34, whose strands have a total cross section of 0.39 mm ² , and then this with the bare ends 24, 26 of the strands 28, 30 are welded to the node 32, which in principle in the Fig. 1 Id is shown.

By dimensioning in this regard, the cross section of the intermediate node is more than 7% of the total cross section and thus meets the requirements of relevant industries.

In order to weld the intermediate node 34 in one and the same ultrasonic welding device as the end node 32, according to the teaching of the invention, the counter electrode of the ultrasonic welding device 110 shown in principle in Fig. 1 is formed such that two sections each having a working surface of different dimensions and / or structuring Are available to selectively weld the intermediate node 34 and the end node 32 can. Instead of a final node, a transit node could also be welded. This will be clarified with reference to FIGS. 2 to 4. This is a detail of one of Fig. 1 corresponding ultrasonic welding device can be seen.

In Fig. 2, the ultrasonic welding device is shown with an open compression space 42 which is delimited by a first boundary surface 44 of a sonotrode 46, which has a structure with respect to the sonotrode head, as in EP 1 680 254 Bl, the disclosure of which is expressly incorporated by reference. Opposite to the first boundary surface 44 of the sonotrode 46 designed as a longitudinal oscillator, the compression space 42 when it is closed is delimited by a second boundary surface 48 or 50, the counterelectrode 56 associated with a first section 52 or a second section 54 of a sonotrode 46 is formed. The sections 52, 54 of the counter electrode, also referred to below as the anvil 56, will be discussed in more detail below.

A third boundary surface 58 of the compression space 42 is formed by a side slider 60. The boundary surface 62 of the compression space 42 opposite the third boundary surface 58 is formed by a delimiting element 64 to be designated as a spotting plate 64. The spotting plate 64 is adjusted in the drawing as a unit with the anvil 56 vertically, ie perpendicular to the first boundary surface 44 and with a small gap along the head of the sonotrode 46, as is well known from the prior art.

The compression space 42 has a rectangular cross-section with open end faces, which are penetrated by the longitudinal axis of the compression space 42. According to the invention, the counterelectrode 56 consists of a first or lower section 54 and a second or upper section 52 which, when used transverse to the longitudinal axis of the compression chamber 42, can have diverging widths. Thus, it is possible to easily weld strands of different cross-sections. In this case, the working surface 50 of the first portion 54 has a smaller width and thus smaller extent transverse to the longitudinal axis of the compression space 42 and thus the longitudinal axis of the sonotrode 46 as the working surface 48 of the second portion 52. For this purpose, the first portion 54 has a projection which has a rectangular shape in section parallel to the boundary surface 44 and faces the first boundary surface 44 of the sonotrode 46 serving as a welding surface or work surface. The parallel to the first boundary surface 44 extending surface of the projection 66 (portion 54 of the counter electrode 56) thus forms the first working surface 50 of the anvil 56. With the first working surface 50, the strands 12, 14, 16, ie their bare ends 28, 30th , 32 welded to the intermediate node 34, when according to the illustration of FIG. 4 in the compression space 42, the strand ends 18, 20, 22 not shown introduced and the compression chamber 42 is circumferentially closed. Then, the anvil 56 is adjusted in the direction of the sonotrode 46, ie the first boundary surface 44 of the compression space 42, in order in the longitudinal direction, ie in longitudinally excited sonotrode 46 and simultaneous application of force to the strands 12, 14, 16 via the anvil 56 this to the Weld intermediate node 34. The welding surface of the sonotrode 46 is located in the antinode. Before closing the compression chamber 42, the side slider 60 has been adjusted to the required extent in the direction of the spotting plate 64, that is, the fourth boundary surface 62, as is well known in the case of ultrasound-welding devices that are adjustable in height and width.

The strands 12, 14, 16 or a plurality of corresponding strand units, which are also welded to intermediate nodes, are then inserted with further strands of larger cross sections, ie in the embodiment with the strands 28, 30, in the reopened compression chamber 42 of the same ultrasonic welding device to zurückgefahrenem first section 54 to weld the node 32 of FIG. LOD. The closing of the compression space is carried out in accordance with the previous explanations, wherein the first portion 54 extends with its end face 68 in alignment with the fourth boundary surface 62, as is apparent from Fig. 3. The end face 68 in this case forms the fourth boundary surface. The over the end face 68 projecting working surface 48 of the second portion 52 is thus effective working surface during welding.

Instead of several strands of large cross-section, one or more stranded units or intermediate nodes can also be used.

According to the invention, a compaction space 42 is thus provided which can be closed optionally via one of the sections 52, 54 of the anvil 56, wherein the sections 52, 54 have different working surfaces 48, 50 in order to correspond to the cross sections of the strands to be welded Damage to the wires of the strands not leading to allow material bonding. In this case, the intermediate node 34 as shown in FIG. I Ia, IIb at a distance from the insulation 36, 38, 40 is formed to mechanical loads the exposed wires in the transition region to the insulation 36, 38, 40 to avoid, which could otherwise lead to fractures.

Divergent work surfaces include different profiles or different surface extensions or both.

If, as shown in FIGS. 2 to 4, the work surfaces 48, 50 extending from the sections 52, 54 are aligned parallel to the working or welding surface of the sonotrode 46 forming the first boundary surface 44 of the compression space 42, then a section may comprise a plurality of sections existing counterelectrode also have a deviating geometry. This will be clarified with reference to FIGS. 12a, 12b. Thus, as shown in Figure 12a, the free ends of strands 72, 74, 76 are welded to an end node 70 to then insert a notch 78 therein to increase strength. This may be facilitated by the lower or first portion 54 whose side facing the sonotrode 46 has a projection of circular cut geometry, thus embossing a sectionally arcuate notch 78 in the end node 70 transverse to the longitudinal direction of the strands 72, 74 , 76 runs. The sections 52, 54 are formed as a kind of slide, which are parallel to each other and parallel to the first boundary surface 44, which is provided by the sonotrode 46, adjustable. In this case, the lower portion 54 may be recorded guided by the Tuschierplatte 64. If it is desired to weld or shape the first section 54, it is preferable to adjust the first and second sections 54, 52 as a unit, as shown in FIG. 4.

If it has been explained with reference to the exemplary embodiments that the working surfaces of the sections 52, 54 deviate from one another, the invention will of course not be abandoned even if the work surfaces have the same geometries or extensions.

If the sections 52, 54 of the anvil 56 are arranged one above the other according to the exemplary embodiment, FIGS. 2-4 also provide the option of arranging sections next to one another, as can be seen purely by way of example in FIG. Thus, the counter electrode, ie the anvil 156, has a first section 152 and a second section 154, which are adjustable in one plane. The sections 152, 154 may have different profiles on the compression chamber side, which are intended for welding an end or transit node.

In the exemplary embodiment, the portion 152 of the anvil 156 has a symmetrical profiling, that is, the structure of the work surface 158 is symmetrical to a plane 160 that is perpendicular to the work surface 158 and centrally between the side surfaces 172, 174 of the portion 152. In contrast, section 154 has a working surface 176 which is asymmetrical and thus intended for welding end nodes.

FIG. 6 shows a further embodiment of an anvil 256, which consists of a first section 252 and a second section 254 which is telescopically adjustable relative to the first section 252, ie can be moved into or out of it. The undersides 258, 260 of the sections 252, 254 shown in the drawing form the work surfaces.

A further embodiment of a counter-electrode 356 is shown in FIGS. 7a-7c, which is designed such that the possibility of checking the quality of a welded connection is given. For this purpose, the counter-electrode 356 has a section 358, which in particular is telescopically displaceable relative to the base body 360 of the counter-electrode and has on its underside 362, which faces the welding surface of the sonotrode 346, a projection 364, which is tapered in the exemplary embodiment. The projection 364 can now put on a placed on a surface of a sonotrode welded joint and act with a predetermined test force on the welded joint. Depending on detectable changes in the welded joint, it may then be judged whether the welded joint is proper or faulty. The main body 360 itself can in turn serve with its underside 368 as a working surface in the case of welds to be performed.

Not only the counter electrode or the anvil can have several sections of different designs or geometries, but also the sonotrode. This will be explained with reference to FIGS. 8-10. In the embodiment of FIG. 8, a sonotrode 146 designed as a longitudinal oscillator is shown purely in principle in the section, in which two sections 148, 150 are formed in their sonotrode head having the welding surface, which sections are separated from one another via a step 166. Sections 148, 150 provide work surfaces 162, 164 which are spaced apart and extend in parallel planes. In this case, the working or welding surface 162 of the section 148 has a symmetrical profiling and the working surface 164 of the section 150 has an asymmetrical profiling, as illustrated by the corrugated structure. The running between the working surfaces 162, 164 stage 166 can serve as a stop for strand ends, which are to be welded by means of the asymmetric profiling of the working surface or welding surface 154.

The sections 148, 150 and thus the work surfaces 162, 164 adjoin one another in the longitudinal direction of the sonotrode 146.

If a passageway node is to be welded, then the welding or working surface 162 is used, to which, when the anvil 156 is assigned according to FIG. 5, the section 152 would be aligned. In contrast, section 154 is used when an end node is to be welded by means of work surface 164.

It should be noted, however, that even a terminal node with a symmetrical profile can be welded. FIG. 9 shows a further embodiment of a sonotrode 246, which has two sections 248, 250 on the top side. The section 248 has a working surface 254 which is formed as a welding surface and has a desired profiling. The section 250 has a comb-like or bead-like geometry, that is, in section an arc shape, for example, during the welding of strands at the same time impress a notch in a surrounding envelopes such as pipe cable lug during welding in order to increase the mechanical strength. The corresponding section 250 runs in the exemplary embodiment of FIG. 8 perpendicular to the longitudinal axis of the sonotrode 256. A sonotrode 346 according to the exemplary embodiment of FIG. 10 has a first section 348 for welding certain working surface 354 and a second section 350 intended for welding and embossing, so as to impress a notch in accordance with FIG. 9, for example, into a metallic envelope such as a tubular cable lug , In this case, the longitudinal axis of the bead-like or comb-like section 350 extends in the longitudinal axis direction of the sonotrode 346.

On the basis of the teaching according to the invention, an ultrasonic metal welding machine, in particular in the form of a strand welding machine, is provided, which has a multi-part anvil, using the section which is optimized for the intended welding process. The sections of the anvil can be arranged one above the other, side by side or inside each other. The work surfaces of the sections may be profiled or have geometries to perform additional functions such as crimping or cutting or testing welded joints.

It is also possible to form sonotrodes with sections forming several work surfaces, welding with the section which is optimally suited for the welding process. Also, a work surface for shaping such as embossing can be formed.

On the basis of the teaching according to the invention, knots can be welded with one and the same machine, which would otherwise not be able to be produced or only after replacement of tools or, if successive different welding machines are used.

There is the possibility of optimizing node properties.

Stepped sonotrodes can be used, with one section of the sonotrode being used to weld end nodes and the other section to weld through-holes. A step running between the sections can additionally be used as a stop for conductors to be welded to an end node. It is also possible, when welding end nodes or through-nodes, to ensure that the otherwise frequently existing line ends or projecting individual cores not welded after the ultrasonic welding are at least additionally pressed on. Thus, with a first section, the end node or through-node itself may be welded to then at least press the line ends with the other section.

If the sections of the counterelectrode are preferably adjustable relative to one another, the invention will not be abandoned even if a counterelectrode has at least two unitary sections which have working surfaces deviating from one another, wherein one working surface can be used in particular for welding and the other working surface for shaping ,

Claims

claims

1. A method for welding and / or deforming electrical conductors (18, 20, 22, 24, 26) and / or surrounding envelopes, such as tubular cable lug, with a at least in height, preferably in height and width, adjustable compression space (42) in opposite sides of a portion of a sonotrode (46, 146, 246, 346) as a first boundary surface (44) and at least a portion of a counter electrode (56, 156, 256, 356) as a second boundary surface (48, 50) and preferably in the remaining sides of one of a portion of a side pusher (60) as a third delimiting surface (58) and a portion of a delimiting element (64) as a fourth delimiting surface (62), wherein for welding the counterelectrode and the sonotrode are displaced relative to one another become,

characterized,

in that a counter electrode (56, 156, 256) is used which has sections of work surfaces which differ from one another geometrically or consists of at least two mutually adjustable sections (52, 54, 152, 154, 252, 254) and as sonotrode (46 , 146, 246, 346) is used one of the group comprising a working surface as a welding surface (44), at least two contiguous or adjacent working surfaces with geometrically divergent welding surfaces (162, 164), at least one welding surface (254, 354) as Working surface and a work surface (250, 350) having a coining or shaping function.

2. The method according to claim 1,

characterized,

in that, depending on the electrical conductors (18, 20, 22, 24, 26) to be welded, the portion (52, 54, 152, 154, 252, 254) of the counterelectrode (56, 156, 256) or the welding surface (44, 254, 354) of the sonotrode (46, 146, 246, 346) or both the portion of the anvil and the welding surface.

3. The method according to claim 1 or 2,

characterized,

in a first welding process, electrical conductors (18, 20, 22) are welded to an intermediate node (34) with a first section (54) of the counterelectrode (56) and that in a second welding process the intermediate node is connected to at least one further conductor (24, 26) and / or another intermediate node to a node (70) are welded, wherein in the second welding operation, a deviating from the first portion second portion (52) of the counter electrode is used and / or a welding surface or a welding surface area is used, which of the first welding process is different.

4. The method according to at least one of the preceding claims,

characterized,

in that, with the position of the intermediate node (34) unchanged, it is welded to the further conductor (24, 26) and / or the further intermediate node using the second section (52) of the counterelectrode (56, 256).

5. The method according to at least one of the preceding claims,

characterized,

in a first welding operation, first conductors (18, 20, 22) are welded by means of a first section (54) of the counter-electrode (56) to an end node (34), which is then bent using a second section (52) deviating from the first section the counter electrode is welded and / or deformed.

6. The method according to at least one of the preceding claims, characterized

that a first portion (154) of the counter electrode (156) conductors are welded to a terminal node and with a second portion (152) of the counter electrode conductor to a passage node.

7. The method according to at least one of the preceding claims,

characterized,

that is crimped or cut by means of one of the working surfaces of the counter electrode.

8. The method according to at least claim 1,

characterized,

in that with a section (358) the counter electrode (356) is subjected to a weld joint test.

9. The method according to at least one of the preceding claims,

characterized,

in that, with the working surface (250, 350) of the sonotrode (246, 346) surrounding the shaping or embossing function, a notch is formed in a conductor surrounding the conductor, such as a cable lug, in particular running transversely as perpendicular to the sonotrode longitudinal axis.

10. ultrasonic metal welding device having a, preferably in height and width, adjustable compression space (42) in opposite sides of a portion of a sonotrode (46, 146, 246, 346) as a first boundary surface (44) and at least a portion of a counter electrode ( 56, 156, 256, 356) as a second boundary surface and optionally in the remaining sides of one of a portion of a side pusher (60) as a third boundary surface (58) and a portion of a boundary element (64) as a fourth boundary surface (62) in which, for closing or opening the compression space, a relative movement takes place between the counterelectrode and the sonotrode, characterized in that the counter-electrode (56, 156, 256) has sections with geometrically divergent working surfaces or consists of at least two mutually adjustable sections (52, 54, 152, 154, 252, 254) and the sonotrode (46) has a working surface as welding surface or in that the counter-electrode (56, 156, 256) has sections with geometrically divergent working surfaces or consists of at least two mutually adjustable sections (52, 54, 152, 154, 252, 254) and / or the sonotrode (146, 246, 346) Having at least two adjacent or adjacent work surfaces (162, 164) with geometrically divergent welding surfaces or a work surface as a welding surface and a work surface (250, 350) with shaping or embossing function.

11. ultrasonic metal welding apparatus according to claim 10,

characterized,

that one of the working surfaces of the counter-electrode exerts a welding-independent function, in particular exerts a crimping or cutting function.

12. ultrasonic metal welding apparatus according to claim 10 or 11,

characterized,

in that the counterelectrode (56, 156) has at least two sections (52, 54, 152, 154, 252) which can be displaced parallel to one another and parallel to the working surface (44, 162, 164, 254, 354) of the sonotrode (46, 146, 246, 346) , 254) which selectively limit the compression space.

13. ultrasonic metal welding device according to at least one of claims 10 to 12,

characterized,

the two sections (52, 54, 152, 154) are arranged one above the other or side by side.

14. Ultrasonic metal welding device according to at least one of claims 10 to 13,

characterized,

the sections (252, 254) are telescopically adjustable relative to one another.

15. Ultrasonic metal welding device according to at least one of claims 10 to 14,

characterized,

in that the sections (52, 54, 152, 154, 252, 254) can be actuated via separate drive means, such as cylinders.

16. Ultrasonic metal welding device according to at least one of claims 10 to 15,

characterized,

that the working surfaces (158, 176) at least the counter-electrode (156) have different profiles, wherein with respect to a perpendicular to the respective working surface and this center in the longitudinal direction of the compression space intersecting plane (160) preferably one of the profiles symmetrical and the other is formed asymmetrically or both are formed symmetrically or asymmetrically with divergent structuring.

17. ultrasonic metal welding device according to at least one of claims 10 to 16,

characterized,

in that the sonotrode (146) has two welding surfaces (162, 164) which extend in height-spaced mutually parallel and parallel planes and adjoin or are immediately adjacent.

18. Ultrasonic metal welding device according to at least one of claims 9 to 16, characterized

in that one of the working surfaces (250, 350) of the sonotrode (246, 346) has a comb-like or bead-like, in section arc-shaped geometry whose extension runs parallel or perpendicular to the sonotrode longitudinal axis.

19. ultrasonic welding tool in the form of a counter electrode,

characterized,

in that the counter-electrode (56, 156, 256) has at least two sections (52, 54, 152, 154, 252, 254) with geometrically divergent working surfaces (158, 176) or two mutually adjustable sections.

20. ultrasonic welding tool according to claim 19,

characterized,

in that the adjustable sections (52, 54, 152, 154, 252, 254) are arranged side by side or one above the other or can be telescopically relative to one another.

21. ultrasonic welding tool according to at least one of claims 19 and 20,

characterized,

a portion (358) of the counterelectrode (356) has an element suitable for weld joint testing, such as a projection (364).

22. ultrasonic welding tool according to at least one of claims 19 or 21,

characterized,

that the work surfaces (158, 176) have different profiles from each other.

23. Ultrasonic welding tool in the form of a sonotrode,

characterized,

in that the sonotrode (146) has at least two welding surfaces (162, 164), wherein the welding surfaces extend in planes spaced apart from one another and extend parallel to one another and adjoin one another or are spaced from one another, and / or one of the welding surfaces (250, 350). has a comb or bead-like geometry whose extension is parallel or perpendicular to the sonotrode longitudinal axis.