CONTROL

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Utility Patent

Application No. 15/343,612 filed on November 4, 201 6 and also claims the benefit of U.S. Provisional Application No. 62/253,742 filed on November 1 1 , 2015. The entire disclosures of the above applications are incorporated herein by reference.

FIELD

[0002] The present disclosure relates to a work piece processing device with a servo-elastic actuator system having simultaneous precision force and position control.

BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Work piece processing devices as used herein are devices that apply force to a work piece (or work pieces) during processing of the work piece. In some devices, the force is part of and contributes to the performance of the work on a work piece (or work pieces), such as in welding, and in other cases, the force is not part of the performance of the work on the work piece but rather is applied to clamp the work piece in place as the work is performed on the work piece. Such work processing devices have actuators that apply the force to the work pieces such as by moving a tool against the work piece or applying a clamp to the work piece to hold it in place during processing. Such work piece processing devices can include devices for ultrasonic, vibration, laser, thermal, spin or infrared processing of plastics or metal where force is applied to the work piece, such as welding, staking, swaging, and cutting. Work piece processing devices that apply force to the work piece during processing need actuators that can control both force and position.

[0005] Pneumatic actuators are good at providing a constant force regardless of the actuator's position when in contact with a relatively stiff surface, but are not very precise at controlling position. Servo-actuators on the other hand are precise at controlling position but not that good at controlling force when in contact with a relatively non-compliant or stiff surface. A servo-actuator is a mechanism that provides position controlled motion in a mechanical system in response to an electrical input signal using feedback of an output of the servo actuator for position control.

[0006] Previous use of servo-actuators for ultrasonic welding, vibration welding, laser welding, thermal welding, spin welding, infrared welding and ultrasonic cutting could control position very accurately, on the order of a thousandth of an inch, but could not control force to under plus or minus 40 pounds. The problem arises from the relative non-compliance of the material of the work piece being pressed against during welding. Even though the servo-actuators can resolve the position to within a thousandth of an inch, this small relative motion, given the stiffness of the material being pressed against, results in a large change in force -- on the order of about 40 pounds for a typical piece of plastic, and even higher for a piece of metal. This problem of force to position sensitivity is inherent with servo-actuators when pushing against a relatively non-compliant surface, regardless of how good the control system is for the servo-actuator.

[0007] Servo actuators often have a torque control mode that gives a degree of control of the force, such as that described in US Patent 8,720,516 for "Ultrasonic Press Using Servo Motor with Delayed Motion." But again, because of the noncompliance of the surface being pushed against, the force varies by a high percentage of the total load.

[0008] One well understood method in the prior art to control force precisely with a servo-actuator is to have the servo-actuator press against a long travel spring. This gives very good force control, but does not have any position control. US Patent 4,817,848 for "Compliant Motion Servo" discloses the use of a long travel spring with a servo-actuator to control force, but switches over to a closed loop position control at the end of motion, and therefore loses control of force at the end of the process.

[0009] In many processes, there is a need for precise force control of actuation, while maintaining precise position control. Specifically, in ultrasonic, vibration, laser, thermal, spin or infrared processing of plastics or metal where force is applied to the work piece, such as welding, staking, swaging, and cutting, there is a need for simultaneous precise force control and position control of actuation.

SUMMARY

[0010] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0011] In accordance with an aspect of the present disclosure, a work piece processing device includes a tool piece, a work piece holder, and a servo- elastic actuator system having simultaneous precision force and position control that moves one of the tool piece and the work piece holder to the other of the tool piece and work piece holder. In accordance with an aspect, the servo-elastic actuator system includes a servo-actuator and one or more elastic members mechanically coupled with each other (directly or indirectly through another component or components) in a force transmission path. In an aspect, the force transmission path is a linear force transmission path and in an aspect is a rotational force transmission path (i.e., a torque transmission path).

[0012] In accordance with an aspect, the servo-actuator includes a servo-motor and an actuator member coupled to the servo-motor. The servo-motor and the work piece holder are affixed to a frame of the work piece processing device, an end of the elastic member is affixed to an end of the actuator member and an opposite end of the elastic member affixed to the tool device.

[0013] In accordance with an aspect, the servo-actuator includes a servo-motor and an actuator member coupled to the servo-motor. The elastic member is disposed between the servo-motor and a frame of the work piece processing device with the tool device affixed to an end of the actuator member, the work piece holder affixed to the frame.

[0014] In accordance with an aspect, the servo-actuator includes a servo-motor and an actuator member coupled to the servo-motor. The elastic member is disposed between the work piece holder and a frame of the work piece processing device and the tool device is affixed to an end of the actuator member.

[0015] In accordance with an aspect, the servo-actuator includes a servo-motor and an actuator member coupled to the servo-motor. The elastic member is disposed between lower and upper portions of a frame of the work piece processing device. The work piece holder is affixed to the lower portion of the frame and the servo-motor is affixed to the upper portion of the frame and the tool piece affixed to an end of the actuator member.

[0016] In accordance with an aspect, the servo-actuator includes a servo motor and an actuator member coupled to each other through an elastic member. The work piece holder is affixed to the lower portion of the frame and the servo-motor is affixed to the upper portion of the frame and the tool piece affixed to an end of the actuator member.

[0017] In accordance with an aspect, the elastic member is in one of torsion, compression or tension as the servo actuator moves.

[0018] In accordance with an aspect, the work piece processing device includes a plurality of elastic members where each elastic member is in one of torsion, compression or tension as the servo actuator moves. In accordance with an aspect, elastic members are disposed in different ones of two or more of the above locations.

[0019] In accordance with an aspect, a controller is coupled to the servo-actuator wherein the controller is configured to control movement of the servo-actuator to an end position based on force being applied to a work piece held by the work piece holder and a force set-point, moving the servo-actuator to maintain the force being applied to the work piece at the force set-point once the force being applied to the work piece reaches the force set-point, and stopping movement of the servo-actuator when the servo-actuator reaches a maximum travel.

[0020] In accordance with an aspect, the controller is configured to determine the force being applied to the work piece as the elastic member is deflected based on a spring deflection of the elastic member.

[0021] In accordance with an aspect, first and second position sensors are disposed on opposite sides of the elastic member and coupled to the controller. The controller is configured to determine the spring deflection of the elastic member based on positions sensed by the first and second position sensors as the elastic member is deflected by movement of the servo-actuator.

[0022] In accordance with an aspect, a position sensor is disposed between opposed ends of the elastic member that senses the spring deflection of the elastic member as the elastic member is deflected. The position sensor is coupled to the controller.

[0023] In accordance with an aspect, a force sensor is coupled to the controller that senses the force being applied to the work piece. In accordance with an aspect, the force sensor is a torque sensor that senses torque applied between the servo-motor and the actuator member.

[0024] In accordance with an aspect, the controller is configured to limit maximum travel of the servo-actuator based on a position sensed by a position sensor and a position set-point.

[0025] In an aspect, the controller is configured to limit maximum travel of the servo-actuator based on an overshoot distance compensation as well as the position sensed by the position sensor and the position set-point.

[0026] In accordance with an aspect of the present disclosure, the work piece processing device is any of an ultrasonic welder, a vibration welder, a laser welder, a thermal welder, a spin welder, an infrared welder, or an ultrasonic cutter

[0027] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0028] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. The orientation of the drawings are not intended to limit the actual orientation of the servo-elastic actuator system relative to the work piece being processed. Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0029] Fig. 1 A is simplified schematic view of a work piece processing device having a servo-elastic actuator system in accordance with an aspect of the present disclosure;

[0030] Fig. 1 B is a simplified schematic view of a work piece processing device having a variation of the servo-elastic actuator system of Fig. 1 A in accordance with an aspect of the present disclosure;

[0031] Fig. 2 is simplified schematic view of a work piece processing device having another servo-elastic actuator system in accordance with an aspect of the present disclosure;

[0032] Fig. 3 is simplified schematic view of a work piece processing device having another servo-elastic actuator system in accordance with an aspect of the present disclosure;

[0033] Fig. 4 is simplified schematic view of a work piece processing device having another servo-elastic actuator system in accordance with an aspect of the present disclosure;

[0034] Fig. 5 is a control diagram of control logic for controlling a servo-actuator of the servo-elastic actuator systems of any of Figs. 1 A, 1 B - 4;

[0035] Fig. 6 is a control diagram of control logic that is a variation of the control logic of Fig. 5;

[0036] Fig. 7 is a control diagram of control logic that is another variation of the control logic of Fig. 6;

[0037] Fig. 8 is a flow chart of control logic for determining an offset distance compensation in accordance with an aspect of the present disclosure; and

[0038] Fig. 9 is a simplified schematic view of a work piece processing device having another servo-elastic actuator system in accordance with an aspect of the present disclosure.

[0039] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0040] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0041] In accordance with an aspect of the present disclosure, a work piece processing device in which force is applied against the work piece during processing has a servo-elastic actuator system that applies the force to the work piece. The servo-elastic actuator system includes an elastic member, such as a spring or elastomer, mechanically disposed with a servo-actuator in a force transmission path to create additional compliance in the system in order to adjust force versus position sensitivity ratio. This allows the force to be controlled accurately with the servo-actuator, while retaining accurate position control. In should be understood that the force transmission path can be a linear force path or a rotational force transmission path (that is, a torque transmission path).

[0042] The servo-actuator controls position to a given precision. The spring constant of the elastic member if using a linear spring constant is chosen to achieve a certain force precision by the following equation:

K=AF/Ax (1 )

where:

K = spring constant of elastic member;

AF = precision of force; and

Δχ = given precision of position of servo-actuator.

[0043] If using a torsional spring constant, the torsional spring constant is chosen to achieve a certain torque precision by the following equation:

Κ _θ =ΔΤ/ Δθ (2)

where:

Κ _θ = spring constant of spring or elastomer;

ΔΤ = Torque; and

ΔΘ = Angular revolution.

[0044] In an aspect, the elastic member is in series with the servo- actuator relative to the frame, discussed in more detail below with reference to Figs. 1 A, 1 B - 3, or in parallel with the servo-actuator on the frame itself, discussed in more detail below with reference to Fig. 4. In each case, the elastic member is in series with the servo-actuator in a force transmission path and the overall spring constant is reduced relative to the surface being pushed against to raise the force sensitivity of the servo-actuator.

[0045] Figs. 1 - 4 show different example embodiments of work piece processing devices having servo-elastic actuator systems in accordance with aspects of the present disclosure. The work piece processing devices can be any device that applies force to the work piece during processing. The work piece processing devices can, for example, be devices for ultrasonic, vibration, laser, thermal, spin or infrared processing of plastics or metal where force is applied to the work piece, such as welding, staking, swaging, and cutting. The work piece processing systems can also be devices where force is applied to the work piece to hold it in place during processing.

[0046] With reference to Fig. 1 A, a work piece processing device 100 includes a servo-elastic actuator system 102. Servo-elastic actuator system 102 includes a servo-actuator 104 and elastic member 106. Servo-actuator 104 includes a servo-motor 108 and an actuator member 1 10 coupled to servo-motor 108 that is moved up and down (as oriented in the drawings) by servo-motor 108. Servo-motor 108 is coupled to a controller 1 12 that controls servo-motor 108. Servo-motor 108 is affixed to a frame 1 14 of device 100. An end 105 of elastic member 106 is affixed to an end 1 16 of actuator member 1 10 and an opposite end 107 of elastic member 106 is affixed to a tool device 120. Device 100 also includes a work piece holder 122, which for example could be an anvil of an ultrasonic welder or ultrasonic tube sealer. Work piece holder 122 is affixed to frame 1 14 of device 100. A work piece 124, which has a relatively non-compliant or stiff surface 126, is situated on work piece holder 122. Work piece 124 is a work piece that is to be processed by device 100. Work piece 124 can for example be two plastic or metal pieces that are to be ultrasonically welded together when device 100 is an ultrasonic welder. Work piece 124 can for example be a tube that is to have an end ultrasonically sealed when device 100 is an ultrasonic tube sealer. Tool device 120 is that part of work piece processing device that is pressed against work piece 124 by the movement of servo-actuator 104 to process work piece 124. Tool device 120 may for example be an ultrasonic stack of an ultrasonic welder or an ultrasonic sealer and a tip of an ultrasonic horn of the ultrasonic stack is what physically contacts work piece 124. In such cases, tool device 120 is energized ultrasonically to work on work piece 124 to process it, such by ultrasonic welding or ultrasonic sealing, as applicable.

[0047] In Fig. 1 B, work piece processing device 100' has elastic member 106 disposed between actuator member 1 10 and servo motor 108. Otherwise, work piece processing device 100' is the same as device 100 in Fig. 1 A.

[0048] In Fig. 2, work piece processing device 200 has elastic member 106 disposed between servo-motor 108 of servo-actuator 104 and frame 1 14 and tool device 120 is affixed to end 1 16 of actuator member 1 10. Otherwise, work piece processing device 200 is the same as work piece processing device 100.

[0049] In Fig. 3, work piece processing device 300 has elastic member 106 disposed between work piece holder 122 and frame 1 14 of work piece processing device 300. Otherwise, work piece processing device 300 is the same as work piece processing device 100.

[0050] In Fig. 4, work piece processing device 400 has a frame 402 having an upper frame portion 404 (as oriented in Fig. 4) and a lower frame portion

406 with elastic member 106 disposed between upper frame portion 404 and lower frame portion 406. Work piece holder 122 is affixed to lower frame portion 406.

Servo-motor 108 of servo-motor 108 is affixed to upper frame portion 404.

Otherwise, work piece processing device 400 is the same as work piece processing device 100.

[0051] In operation, servo-actuator 104 moves tool device 120 into contact with work piece 124 and servo-actuator 104 will thus be pushing against the relatively non-compliant surface of work piece 124. When pushing against a relatively non-compliant surface, the ratio of force to position sensitivity of the servo-actuator is determined by the spring constant of the material being pushed upon. Having elastic member 106 in series with servo-actuator 104 in the force transmission path through which force is applied against the work piece 124 when the tool device 120 is brought into contact with work piece 124 adds an additional compliance to the system, which reduces the overall spring constant. This increases the force sensitivity of the servo-actuator 104 relative to its position. This allows the force to be controlled accurately with the servo-actuator 104 while maintaining accurate position control. The spring constant of the elastic member 106 is selected to provide a desired force to position fidelity.

[0052] In servo-elastic actuator system 102, elastic member 106 will expand after servo-actuator 104 stops moving tool device 120, thus changing the position of elastic member 106 after movement of tool device 120 stops. Reactive controls, discussed in more detail below, are used to compensate for this by countering this movement of elastic member 106. With this compensation, the accuracy of position is the original position resolution of servo-actuator 104.

[0053] In an aspect, a simple algorithm using the spring constant of the elastic member 106 and the spring deflection is used to calculate the force being applied to work piece 122 when tool device 120 is brought into contact with work piece 122 by servo-actuator 104. The spring deflection is the amount in distance that elastic member 106 is deflected. A closed loop of this calculated force of the elastic member 106 controls the position of servo-actuator 104. By this means, precise control of the force being applied to work piece 124 can be achieved while simultaneously precisely controlling position of the tool device 120.

[0054] While springs and elastomers were discussed above as examples for elastic member 106, it should be understood that elastic member can be any type of member that has the requisite spring constant (linear or torsional as applicable), and can include combinations of elements such as a plurality of elastic members 106 positioned in different positions in the work piece processing device. Fig. 9 shows an example of a work piece processing device 900 having a plurality of elastic members 106 positioned in different positions in work piece processing device 900. In this example, the different positions are the positions described above with reference to Figs. 1 A, 1 B - 4. It should be understood that the plurality of elastic members could be positioned in other than all these positions. For example, the plurality of elastic members could be positioned in some but not all of these positions.

[0055] It should be understood that the work piece processing device could be configured so that the work piece holder is moved by servo-actuator 104 against tool device 120. [0056] Fig. 5 shows a control diagram of exemplar control logic 500 for control of servo-motor 108 of servo-elastic actuator system 102 in accordance with an aspect of the present disclosure. Control logic 500 is illustratively implemented in controller 1 12. The control logic 500 uses two position sensors 502, 504, which in an aspect are position encoders, to determine the spring deflection of elastic member 106. Position sensors 502, 504 are located in the work piece processing device so that they are on opposite sides of elastic member 106. By way of example and not of limitation and with reference to device 100 shown in Fig. 1 , position sensor 502 senses the position of end 105 of elastic member 106 and position sensor 504 senses the position of end 107 of elastic member 106 as servo-actuator 104 moves tool device 120 into contact with work piece 124. The difference in the positions sensed by position sensors 502, 504 is determined by summer 506 which subtracts the position sensed by position sensor 504 from the position sensed by position sensor 502 with this difference being the spring deflection of elastic member 106. The force being applied to work piece 124 is calculated at 508 using equation 1 above and the force calculated at 508 input to a PID (proportional-integral-differential) controller 510. It should be understood that alternatively a PI (proportional-integral), P (proportional) or I (integral) controller could be used. A force set-point 512 is also input to PID controller 510. PID controller 510 controls servo-motor 108 and thus controls the position of servo- actuator 104 based on the calculated force (calculated at 508) of elastic member 106. It should also be understood that alternatively, any appropriate closed loop control methodology using the calculated or measured force could be used.

[0057] The position sensed by position sensor 504 is also used to limit the maximum travel of servo-actuator 104. A position set-point 514 is input to a summer 516 as is an overshoot distance compensation 518 and the position sensed by position sensor 504. Summer 516 subtracts the sum of the overshoot distance compensation 518 and the position sensed by position sensor 504 from position set-point 514 and stops servo-motor 108 when the sum of the position sensed by position sensor 504 and the overshoot distance compensation 518 exceed the position set-point 514. In an aspect, overshoot distance compensation 518 is be determined using a test sample to measure an overshoot distance to use as the overshoot distance compensation, discussed in more detail below with reference to Fig. 9, or determined using an iterative method of past samples to estimate the overshoot distance compensation.

[0058] Fig. 7 shows a control diagram of control logic 600 for control of servo-motor 108 of servo-elastic actuator system 102 that is a variation of control logic 500 and only the differences will be discussed. A position sensor 602 disposed between opposed ends of elastic member 106, such between ends 105, 107 (Fig. 2) of elastic member 106, senses the spring deflection of elastic member 106 and is used to obtain the spring deflection of elastic member 106 instead of position sensors 502, 504. Position sensor 504 is still used in the control limiting the maximum travel of servo-actuator 104.

[0059] Fig. 7 shows a control diagram of control logic 700 for control of servo-motor 108 of servo-elastic actuator system 102 that is a variation of control logic 500 and only the differences will be discussed. Control logic 700 uses a force sensor 702 to obtain the force being applied to work piece 124 instead of calculating this force based on the spring constant of elastic member 106 and the spring deflection of elastic member 106. The force sensed by force sensor 702 is input to PID controller 510 in lieu of the force calculated at 508 in control logic 500 and control logic 700 thus also does not use position sensor 502. Position sensor 504 is still used in the control limiting the maximum travel of servo-actuator 104. In an aspect, force sensor 702 is a torque sensor that senses torque applied between servo-motor 108 and actuator member 1 10.

[0060] Fig. 8 shows a flow chart of control logic 800 for determining overshoot distance compensation 518 by using a test sample to measure an overshoot distance to use as the overshoot distance compensation 518. The following discussion is in the context of a work piece processing device that is a welder, such as an ultrasonic welder, but it should be understood that it is applicable to the other types of work piece processing devices. The control logic 800 starts at 802. At 804, the control logic 800 determines whether the work piece processing device is being used in the measurement of an overshoot distance using a sample weld or being used for a regular weld. In this context, a regular weld is the welding of the work pieces together for their intended use. If a regular weld, the control logic 800 branches to 806 where the work piece processing device is used for a regular weld where it performs the weld with the overshoot distance compensation 518 (as discussed above) and then branches to 808 where it determines whether the work piece processing device will be used to perform another weld. If so, the control logic 800 branches back to 804. If not, the control logic branches to 810 where it "stops" the work piece processing device - for example, idles the work piece processing device until it is used again. If at 804 the control logic determines that an overshoot distance to use as the overshoot distance compensation is to be measured using a sample weld, it branches to 812 where it performs a sample weld with the overshoot distance 518 compensation set to zero. At 814, an overshoot distance is measured after the collapse of the sample weld and set as the overshoot distance compensation 518. The control logic 800 then branches to 816 where the total collapse is compared to the desired collapse to see if it is in tolerance. If it is not, the control logic 800 branches to 818 where is performs a sample weld using the overshoot distance compensation 518. From 818, the control logic continues to 814, then to 816 again. If the total collapse is in tolerance of the desired collapse at 816, the control logic 800 branches to 804. In this way, control logic 800 hones into the desired overshoot distance 518 by successive iterations of sample welds.

[0061] Controller 1 12 can be or includes any of a digital processor (DSP), microprocessor, microcontroller, or other programmable device which are programmed with software implementing the above described logic. It should be understood that alternatively it is or includes other logic devices, such as a Field Programmable Gate Array (FPGA), a complex programmable logic device (CPLD), or application specific integrated circuit (ASIC). When it is stated that controller 1 12 performs a function or is configured to perform a function, it should be understood that controller 1 12 is configured to do so with appropriate logic (such as in software, logic devices, or a combination thereof), such as control logic 500, 600 or 700, and also control logic 800 as applicable. When it is stated that controller 1 12 has logic for a function, it should be understood that such logic can include hardware, software, or a combination thereof.

[0062] When a member, component, element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another member, component, element or layer, it may be directly on, engaged, connected or coupled to the othermember, component, element or layer, or intervening components, members, elements or layers may be present. In contrast, when a member, compoinent, element or layer is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another member, compoinent, element or layer, there may be no intervening members, components, elements or layers present. Other words used to describe the relationship between members, components, elements or layers should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0063] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.