The Calculation of the Magnetoelastic Sensor for Controlling the Quality of Welded Joints during Ultrasonic Welding of Plastic Materials

The article provides an overview of the existing methods of ultrasonic energy batching during ultrasonic welding. A method of limiting the duration of an ultrasonic pulse is considered. The method is based on the control of energy parameters of the ultrasonic vibrations passing through the welded product and the support structure on which welding is performed. The experimental studies confirmed a clear correlation between the vibration amplitude and the heating of the samples as well as their thickness and properties. This correlation is called the kinetic characteristic. The use of this characteristic to determine the optimal welding time allows stabilizing the quality of welded joints. The kinetic characteristic for ultrasonic welding is determined using a special sensor support. The article presents a method of calculating magnetoelastic sensors to obtain kinetic characteristics of polymeric materials. Based on the calculations, a magnetoelastic sensor with nickel working element is designed and manufactured. It is used to measure vibration amplitude of the sensor support and determine the kinetic characteristics of polyethylene, polymethylmethacrylate and other polymeric materials. The article describes a method of collateral control with respect to the kinetic characteristic that is used to develop ultrasonic welding equipment. It allows improving the accuracy of measurement of vibration amplitude of the waveguide and the support during ultrasonic welding.

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