Design of ultrasonic-assisted welding sliding table based on TRIZ theory

For the current stage of ultrasound-assisted welding process, there are problems such as ultrasonic energy decay, difficulty to control impact parameters stable when manual handling ultrasonic amplitude rod for impact and more test pieces easily causing work fatigue, an innovative design of welding sliding table based on TRIZ theory was proposed. Functional analysis was used to find root cause of those problems, which was transformed into a contradiction matrix. By analyzing the contradiction matrix, the existing equipment was improved and optimized by selecting appropriate invention principle. Welding platform was replaced by a three-dimensional sliding table in this paper and PLC was used for control, and welding gun and ultrasonic amplitude rod were connected by fixture to realize ultrasonic assisted sliding welding. Finally, welding tests were carried out with the optimized welding sliding table. Operating capability of welding sliding table was checked by changing ultrasonic power, and metallographic observation and mechanical properties of the welded parts were tested. The results showed that based on TRIZ theory, test pieces were welded with welding sliding table, microstructure was improved, tensile strength of welded joints was improved and its width of HAZ was in line with performance requirements. In this paper, welding sliding table was driven by a three-axis full servo motor, which increased stability and accuracy of welding process. By installing a cylinder on welding fixture, ultrasonic impact effect was ensured, and ultrasonic assisted welding process was effectively replaced for manual work.Highlights: TRIZ theory was combined with mechanical expertise and experimental testing of prototypes was conducted to make design process more rational.