Optimized Design of the Horn of Ultrasonic Roll Welding

Abstract

Previous studies on the amplitude horn only calculated sizes in consistent with the axial resonant mode frequency and disc bending resonant mode frequency without considering the overall stress and the amplitude of the disc’s outer ring. The resonant frequency of the amplitude horn cannot occur around 35 kHz. Such a design results in the inability to weld and may damage solar panels or lead to poor welding quality. Using the optimization method to address these problems, the proposed design process in this study is to conduct sensitivity analysis by the gradient method to understand the impact of design variables on the objective function for the selection of design variables. Then, this study applied the random search method to find out the feasible design of arrays to optimize the structure of two arrays closest to the design objective by the full factorial experiment method to ensure to get the global optimal solution rather than the local optimal solution. Finally, by design examples, this study used the sub-problem approximation method to search the optimized solution and compared the differences of the two methods, in order to confirm whether the objective of optimized design of amplitude horn had been achieved.