Abstract: A holding structure (2) in an ultrasonic vibration welding device that welds workpieces by applying ultrasonic waves to the workpieces holds an ultrasonic vibration transmitter (horn) (5) bearing the transmission of longitudinally vibrating ultrasonic waves in holding members (8, 8). The horn comprises a horn body (51) having the length of one-half the wavelength ? of the ultra-sonic vibration. Holding structure (2) includes holders (7x, 7y) having a prescribed volume and thin sheet connectors (6a, 6b) placed at different positions (Pa, Pb) on the horn body (51). The horn body (51) is fixed to holding members (8, 8) by means of the respective holders (7x, 7y).

Abstract: An ultrasonic system has a piezoelectric powered ultrasonic stack having a piezoelectric ultrasonic converter excited by an ultrasonic power supply.

Abstract: Sensors incorporated within a laser channel detect laser light upconverted by a dopant. The dopant is located after a delivery end of a laser delivery optical fiber and upconverts laser light that has traveled from a laser light source from a laser bank through one of a plurality of laser channels through to a location after the delivery end of a laser delivery optical fiber. In some embodiments, the dopant is positioned at the delivery end of the laser delivery optical fiber. In other embodiments, the dopant is positioned within a dummy part or on a surface of at least a work piece.

Abstract: A loose stack joint and/or cracked ultrasonic stack component of an ultrasonic stack of an ultrasonic device are detected by measuring a test damping coefficient with a test scan of the ultrasonic stack. The test damping coefficient is compared with a previously measured baseline damping coefficient. It is determined that the ultrasonic stack has a loose stack joint and/or a cracked ultrasonic stack component when the damping coefficient is greater than the baseline damping coefficient by more than a predetermined amount.

Abstract: Methods of mitigating current overload of an ultrasonic system having an ultrasonic stack under load at startup are provided. The methods include beginning an ultrasonic cycle in the ultrasonic system having the ultrasonic stack that runs a closed loop phase control through the weld cycle by ramping up the power of the ultrasonic stack under load. During ramping up of the power of the ultrasonic stack under load, a controller lowers the phase to a negative phase. After ramping up the power of the ultrasonic stack under load is complete, the controller raises the phase to 0 degrees and the ultrasonic stack is operating at steady state and with the phase at 0 degrees.

Abstract: Sensors incorporated within a laser bank detect light emitted by light sources that is directed into and travels through a delivery end of an associated laser delivery optical fiber. The light sources may be positioned between downstream of the delivery end of the associated laser delivery optical fiber and a lower tooling. In some embodiments, the light source is incorporated within a waveguide. In other embodiments, the light source is positioned within a dummy part.

Abstract: Sensors comprising optical sensor fibers detect a laser light output from at least a laser delivery optical fiber to provide feedback of the laser light intensity detected by the optical sensor fiber. The optical sensor fibers may be integrated within a laser delivery bundle, or may be positioned between a delivery end of the laser delivery optical fiber and a plurality of work pieces to be welded. In various aspects, the feedback provided from the optical sensor fibers is used to control the laser light intensity or to alert an operator that the laser light intensity has fallen below a predetermined parameter.

Abstract: Plastic parts are welded in a laser welding system. An infrared laser source in a laser chamber is controlled by a controller using closed-loop feedback control with a corrected feedback signal that is compensated for background infrared radiation in the laser chamber. Prior to the infrared laser source being turned on, the controller senses with the optical sensor an intensity of background infrared radiation in the laser chamber. Once the laser is on, the controller senses with the optical sensor an intensity of infrared laser radiation in the laser chamber. The controller calculates the corrected feedback signal by subtracting the intensity of the background infrared radiation sensed when the infrared laser source was off from the intensity of the infrared laser radiation sensed when the infrared laser source is on.

Abstract: A holding structure (2) in an ultrasonic vibration welding device that welds workpieces by applying ultrasonic waves to the workpieces holds an ultrasonic vibration transmitter (horn) (5) bearing the transmission of longitudinally vibrating ultrasonic waves in holding members (8, 8). The horn comprises a horn body (51) having the length of one-half the wavelength ? of the ultra-sonic vibration. Holding structure (2) includes holders (7x, 7y) having a prescribed volume and thin sheet connectors (6a, 6b) placed at different positions (Pa, Pb) on the horn body (51). The horn body (51) is fixed to holding members (8, 8) by means of the respective holders (7x, 7y).

Abstract: An ultrasonic welder includes dynamic adjustment of a weld parameter used to control welds of weld cycles during serial operation of the ultrasonic welder. The ultrasonic welder includes a power supply controlled by a controller and the controller sets a value of the weld parameter for a next weld cycle based on a value of a stack heat energy parameter indicative of heat energy in the ultrasonic stack prior to beginning the next weld cycle. The controller controls the power supply based on the value set for the weld parameter to control a weld in the next weld cycle.

Abstract: A baffled optical waveguide has a body shaped to partially or wholly surround a part or parts being processed by being illuminated with light. The body has optical baffles therein that define light channels through which the light travels as it transits the baffled optical waveguide. Outlets of the light channels are adjacent an opening in the body which receives an area or areas of the parts or parts being processed. Each light channel homogenizes the light as it transits through that light channel. The optical baffles that define the light channels keep light from diverging in the baffled optical waveguide as it transits through the light channels. In an aspect, a part (or parts) is processed by illuminating it with light via the baffled optical waveguide.

Abstract: A broken piezoelectric material in an ultrasonic transducer of an ultrasonic stack of an ultrasonic device is detected by measuring a test piezo coupling constant with a test scan of the ultrasonic stack. The test piezo coupling constant is compared to a previously measured baseline piezo coupling constant. The piezoelectric material is determined to be broken when the test piezo coupling constant is less than the baseline piezo coupling constant by more than a predetermined amount.

Abstract: A composite camshaft is made by simultaneous through transmissive laser welding cams, bearing assemblies and load introduction parts to a fiber composite support tube.

Abstract: A copper or aluminum tube is cut and sealed in an ultrasonic tube sealer. A section of the tube is placed laterally in a V-shaped recess of a center member of a forming tool of an anvil of the ultrasonic tube sealer. The anvil and a horn tip are brought together with the center member received in a channel of a forming tool of the horn tip to cut the tube with the cut tube having cut ends on opposed sides of the center member. At least one of the cut ends is pinched together between the forming tool of the anvil and the forming tool of the ultrasonic horn tip and the ultrasonic horn is ultrasonically vibrated to ultrasonically weld the at least one cut end together to seal that cut end.

Abstract: Tooling for an ultrasonic tube sealer includes an ultrasonic horn tip and an anvil. The ultrasonic horn tip and the anvil each have at least one forming tool. The forming tools have a configuration that form an end of a tube when it is sealed by the ultrasonic tube sealer to be rounded.

Abstract: A large surface area ultrasonic block horn includes one or more shaped elements having a node at a mid-point of the shaped element that is narrower than opposed ends of the shaped element.

Abstract: A work piece processing device includes a tool piece, a work piece holder and a servo-elastic actuator system having simultaneous precision force and position control that moves one of the tool piece and the work piece holder to the other of the tool piece and work piece holder.

Abstract: An ultrasonic horn tip for an ultrasonic horn of an ultrasonic tube sealer has a body with a plurality of sides. At least one of the sides has a pair of spaced apart weld tools configured to contact a portion of a tube being sealed in at least two places along the tube that are spaced from each other when the pair of weld tools contact the tube. An anvil for an ultrasonic tube sealer includes a body having a pair of spaced apart weld pads configured to contact a portion of a tube being sealed in at two places along the tube that are spaced from each other when the anvil contact the tube. A tooling kit for an ultrasonic tube sealer includes the foregoing ultrasonic horn tip and anvil.

Abstract: Tooling for an ultrasonic tube sealer includes an ultrasonic horn tip and an anvil. The ultrasonic horn tip and the anvil each have at least one forming tool. The forming tools have a configuration that form an end of a tube when it is sealed by the ultrasonic tube sealer to be rounded.

Abstract: A large surface area ultrasonic block horn includes one or more shaped elements having a node at a mid-point of the shaped element that is narrower than opposed ends of the shaped element.