Method for Temperature Determination in a Joining Zone

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The invention describes a method for determining the temperature in the joining zone of a vibration welding process, especially for metal ultrasonic welding of dissimilar metals like aluminum and copper. Instead of using traditional thermocouples or infrared sensors, the method cleverly uses the actual metal parts being welded, along with specific measuring leads, as an in situ thermocouple. The measured electrical potential difference, which depends on the temperature difference between a 'cold' and 'hot' point during welding, is matched with calibration data and processed automatically to monitor and control the welding process in real time.

Use CasesContent extracted from patent full text and abstract with AI.

• Quality assurance in the ultrasonic welding of wires and cables, particularly in the automotive and electronics industries
• Process monitoring and control in manufacturing where dissimilar metals, such as aluminum and copper, are joined (e.g., battery terminals, electrical connectors)
• Online, non-destructive testing of weld quality during production
• Integration into automated welding systems for continuous temperature feedback
• Maintenance and optimization of high-reliability wire connections in electric vehicle and electronics assembly lines

BenefitsContent extracted from patent full text and abstract with AI.

• Enables real-time, non-destructive monitoring of the welding temperature without introducing foreign thermocouples or sensors into the weld zone
• Improves the accuracy and reliability of weld quality checks, reducing waste and rework
• Facilitates precise process control for joining dissimilar metals, leading to better mechanical and electrical performance
• Reduces equipment complexity and costs by leveraging the parts themselves as temperature sensors
• Allows seamless integration into automated production environments, supporting quality management and Industry 4.0 initiatives

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Inventors & Applicants

Patent Abstract

The invention relates to a method for determining the temperature in a joining zone in a vibration welding process, wherein a first joining partner (1) and a second joining partner (2) are welded together, characterised in that the first and second joining partners (1, 2) act as a thermocouple, wherein, using a first measuring element (5) contacting the first joining partner (1) at a cold site (3) and a second measuring element (10) contacting the second joining partner at a distance from a hot site (8), a potential difference (P1) between the first and second joining partners (1, 2) is detected during the welding process; wherein the second measuring element (10) has a higher temperature than the temperature of the cold site (3) in the region of contact with the second joining partner (2) and has a material of the same type as the second joining partner (2); the potential difference (P1) is compared with material-specific calibration data and processed using a data processing system (7) and the welding process is controlled according to the determined potential difference (P1); the first joining partner (1) is in the form of a multi-wire cable; the first measuring element (5) is in the form of a measuring line, which is connected to the first joining partner (1) by its first end and connected to a data processing system (7) at a measuring point (6) by its second end; the first joining partner (1) and/or the first measuring element (5) are made from aluminium; the second joining partner (2) and/or the second measuring element (10) are made from copper; and the temperature of the cold site corresponds to the ambient temperature of approx. 20° and the contacting takes place in the region of the hot site (8) at a temperature greater than the ambient temperature.