Abstract: A method for monitoring and controlling a vibration welding system includes collecting sensory data during formation of a welded joint using sensors positioned with respect to welding interfaces of a work piece. A host machine extracts a feature set from a welding signature collectively defined by the sensory data, compares and correlates the feature set with validated information in a library, and executes a control action(s) when the present feature set insufficiently matches the information. A welding system includes a sonotrode, sensors, and the host machine. The host machine is configured to execute the method noted above.

Abstract: A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

Abstract: A method for monitoring and controlling a vibration welding system includes collecting sensory data during formation of a welded joint using sensors positioned with respect to welding interfaces of a work piece. A host machine extracts a feature set from a welding signature collectively defined by the sensory data, compares and correlates the feature set with validated information in a library, and executes a control action(s) when the present feature set insufficiently matches the information. A welding system includes a sonotrode, sensors, and the host machine. The host machine is configured to execute the method noted above.