Demonstration of an energy-optimized process control for metal ultrasonic welding based on process characteristic values
Final Report Abstract
In the transfer project "Demonstration of an energy-optimized process control for metal ultrasonic welding based on process characteristic values", or “DEGU” for short, the Institute of Welding and Joining Technology at RWTH Aachen University and its application partner Schunk Sonosystems GmbH have developed the prototype of a model-based process control for ultrasonic metal welding. Ultrasonic metal welding, USMW, is a low-heat joining process and is particularly suitable for welding aluminum and copper materials, which are used, for example, in e-mobility, for power electronics components or in battery technology. Due to increasing complexity and requirements on the one hand and a rapidly growing market on the other, the welding process is increasingly becoming the focus of industrial attention. Despite the industrial spread, process fluctuations can occur in USMW due to base material influences, among other things. These fluctuations can often not be explained, as there is a lack of scientifically sound knowledge regarding the complex interactions between tools and joining parts during the welding process. Based on our own investigations as part of the predecessor project, it has already been shown that information on the thermomechanical processes taking place within the joining zone can be obtained from the measurable vibration behavior of the overall system, consisting of welding tools and joining parts. As part of the DEGU project, further sources of information for characterizing the joint formation were developed in addition to the vibration signals. In addition to the penetration distance and power consumption of the system, the electrical variables in the high-frequency section of the welding system were also made usable. The correlation of the signals with the quality of the weld was demonstrated using quality prediction models. It was shown that the quality of a weld can be predicted based on extracted characteristic values of the aforementioned signals using a statistical model. It should be particularly emphasized that the achieved quality of the welded joint can already be derived with sufficient accuracy from the characteristic values of the first moments of the respective welds. The start of the weld is therefore significantly influenced by the existing external disturbance variables. Accordingly, a control concept was developed with which the total energy input required in the welded joint is determined based on measurements of the first process phases and the end of the process is defined accordingly. In addition to the process signals, the necessary input variables in the model are the quality to be achieved (i.e. test force). Not only the maximum test force can be specified, but also other results of the test, including the fracture behavior.
Publications
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Application of electrical power measurements for process monitoring in ultrasonic metal welding. 75th IIW Annual Assembly and International Conference on Welding and Joining, Annual Commission III Meeting. Tokyo, Japan, 20.7.2022
Müller, F.W.; Chen, C.Y.; Schiebahn, A. & Reisgen, U.
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Application of electrical power measurements for process monitoring in ultrasonic metal welding. Welding in the World, 67(2), 395-415.
Müller, Florian W.; Chen, Chun-Yu; Schiebahn, Alexander & Reisgen, Uwe
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Qualitätsüberwachung beim Metall-Ultraschallschweißen mittels Laservibrometrie. 17. Vibrometerkonferenz – Polytec GmbH. Waldbronn, 11.10.2022
Müller, F.W.; Schiebahn, A. & Reisgen, U.
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Elektromobilität - Ohne die Fügetechnik nicht möglich. Im Blickpunkt - Deutschlands Elite-Institute: Institut für Schweißtechnik und Fügetechnik der RWTH Aachen University, Juli 2023, S. 28 – 31. Inst. f. Wiss. Veröffentlichungen, Lampertheim: ALPHA Informationsgesellschaft mbH. ISSN 1614-8185
Helfers, E.; Müller, F.W.; Schiebahn, A.; Frey, C.; Krichel, T.; Olschok, S. & Reisgen, U.
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Influence of workpiece geometry and natural frequencies on Ultrasonic-Metal-Welding. 3rd International Conference on Advanced Joining Processes, Book Of Abstracts, 19-20 October 2023, Braga, Portugal, Seite 44. Quântica Editora, Lda., Portugal.
Müller, FW; Liu, J.; Schiebahn, A. & Reisgen, U.
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Influence of workpiece geometry and natural frequencies on Ultrasonic-Metal-Welding. AJP 2023 - 3rd International Conference on Advanced Joining Processes. Braga, Portugal, 19.10.2023
Müller, F.W.; Liu, J.; Schiebahn, A. & Reisgen, U.
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Metall-Ultraschallschweißen. Im Blickpunkt - Deutschlands Elite-Institute: Institut für Schweißtechnik und Fügetechnik der RWTH Aachen University, Juli 2023, S. 68-70. Inst. f. Wiss. Veröffentlichungen, Lampertheim: AL- PHA Informationsgesellschaft mbH. ISSN 1614-8185
Müller, F.W.; Helfers, E.; Schiebahn, A. & Reisgen, U.
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From quality prediction to quality control – using ML to optimize the USMW process. 77th IIW Annual Assembly and International Conference on Welding and Joining - 2024 IIW Symposium on Intelligent Welding Manufacturing. Rhodos, Griechenland, 07.07.2024
Müller, F.W.; Schiebahn, A. & Reisgen, U.
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Influence of quality features, disturbances, sensor data and measurement time on quality prediction for ultrasonic metal welding. 77th IIW Annual Assembly and International Conference on Welding and Joining - Annual Commission III Meeting. Rhodos, Griechenland, 10.07.2024
Müller, F.W.; Mirz, C.; Schiebahn, A. & Reisgen, U.
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Influence of workpiece geometry and natural frequencies on ultrasonic metal welding. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 238(12), 2343-2375.
Müller, FW; Liu, J.; Schiebahn, A. & Reisgen, U.
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Joint Quality Assessment of Ultrasonic Metal Welded Parts by Fracture Surface Evaluation. Metals, 14(8), 892.
Müller, Florian W.; Zhao, Haolin; Schiebahn, Alexander & Reisgen, Uwe
