New Method for Determining the Machine-Hand Welding Times Using Ultrasonic Welding Machines with Rotary Sonotrode

Abstract

The paper presents a new method for determining the machine-hand welding times of synthetic polymer materials using ultrasonic welding machines with rotary sonotrode. The method is based on the claims and observations of W. Möller intended for the clothing industry in the 1990s, according to which there is a spontaneous drop in sewing speed when strongly curved seams are joined, which is due to the possibility of human reactions. The method for determining machine-hand sewing times of curved seams was well accepted in garment production processes. It is used to standardize production time. Using ultrasonic welding machines with rotary sonotrode, the problem of determining the time of ultrasonic joining of curved seams on clothing or technical textiles remained unsolved. That is why is completely new and original model was created, which combines eight technical parameters of ultrasonic welds, eight technological parameters of the production process and seven ergonomic parameters depending on the psychophysical conditions of the workers. The systematic development of the mathematical relationship of all 23 parameters mentioned and the corresponding mathematical expressions for determining and calculating these parameters are presented. These results were also verified by experimental measurements, which show a favourable correlation between the calculated and measured machine hand times. The relationships between the recommended welding speeds, the critical radii of curvature and the number of reactions required according to Möller and the new model are also presented. An analysis of the success in the application of Möller’s and the new model was also performed.

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

“…The design of the thin end mainly relies on the wave equation theory of longitudinal vibration. A rotating sonotrode can be used for ultrasonic textiles [23,24], ultrasonic plastic welding [25], ultrasonic atomization [26], and the ultrasonic cold working of metals. Kustron designed two different ultrasonic atomizing devices with different characteristic frequencies based on finite element simulation for the metal powder process, and the amplitude distribution of the two ultrasonic atomizing devices is also similar [27].…”