Continuous loop ribbon welding system

There is provided a method and apparatus for adjoining two ends of a length of impact printer ribbon to form a continuous loop of ribbon. A welding fixture, including a welding anvil, ironing anvil and ultrasonic horn are provided to join the ribbon ends. Tensioning slides are provided to grip the ribbon ends and tension the ribbon during welding operations. A microprocessor controls a series of pistons, switches and solenoids to control the welding sequence.

BACKGROUND OF THE INVENTION 
This invention relates generally to the art of manufacturing ribbon 
cartridges for use with printers for equipment such as computers and word 
processors. More particularly, the invention provides a method and 
apparatus for efficiently and accurately adjoining the ends of a length of 
ribbon so as to form a continuous ribbon loop extending through a ribbon 
cartridge. Still more particularly, the present invention relates to a 
printer ribbon welding equipment system that joins two ribbon ends in a 
cross pattern while controlling the tension of the two ribbon ends at the 
place of joinder. 
Continuous loop printer cartridges are in very common use throughout the 
world. In simple terms, they comprise a length of nylon, or other fabric 
ribbon, loaded in serpentine fashion within a cartridge casing and 
adjoined at the two ends to form a continuous loop. The weakest point 
along the ribbon loop, and thus the point that typically breaks soonest 
during use, is the fusion weld which joins the two ribbon ends. Thus, 
efforts to improve the durability of continuous loop ribbon cartridges 
concentrate on improvements to the method and apparatus for forming the 
weld. 
U.S. Pat. No. 4,629,530, which is expressly incorporated herein by 
reference, describes what is presently the most commonly used method and 
apparatus for joining two ribbon ends to form a continuous loop. The 
method and apparatus described in this patent is a substantial improvement 
over the "crash welding" technique previously in common use. Crash welding 
involves a simultaneous welding and cutting operation which imparts an 
excessive amount of energy into the fabric ribbon, weakening the ribbon 
weld and shortening the expected life of the cartridge. 
In the improved technique described in U.S. Pat. No. 4,629,530, an operator 
clamps the two ribbon ends in criss-cross or x-pattern configuration 
across the top of an anvil having a narrow upper land surface (see FIG. 1 
of U.S. Pat. No. 4,629,530). An ultrasonic horn moves into position above 
the crossed ribbon ends and the anvil, and without crushing the ribbon 
ends to a point of damage against the anvil, imparts ultrasonic energy 
into the ribbon ends, fusing the ribbon ends along a line defined by the 
adjacent land surface of the anvil. 
Next, a separate cutter mechanism severs the two ends of the fused ribbon 
along the edge of the weld line or bead (see FIG. 2 of U.S. Pat. No. 
4,629,530), and a mechanism rotates the upper ribbon 180.degree. to give a 
continuous length of ribbon joined along a diagonal weld bead (see FIG. 3 
of U.S. Pat. No. 4,629,530). The weld formed by this technique leaves a 
distinct nub (see FIG. 4A of U.S. Pat. No. 4,629,530) that is unacceptable 
in terms of ribbon cartridge performance. Consequently, this technique 
typically also includes a second welding operation whereby the weld bead 
on the unfolded ribbon ends is reheated and flattened to reduce the nub to 
acceptable dimensions. 
To achieve maximum weld strength, the ribbon ends must be placed in tension 
during the weld process. U.S. Pat. Nos. 4,629,530 and 3,821,048 disclose 
stretching, or tensioning of the ribbon, prior to and during the welding 
operation. In U.S. Pat. No. 4,629,530, it is noted that the ribbon is held 
taught by the operator before the clamping apparatus grips the ribbon for 
welding. Col. 26, lines 10 to 22. In U.S. Pat. No. 3,821,048, the ribbon 
is tensioned by ribbon tensioning feet which stretch the ribbon into 
ribbon tensioning cavities as the ribbon is gripped in the ribbon 
positioning groove for welding. Col. 4, lines 33 to 42. However, there is 
no disclosure of the need to, or means for, adjusting the tension for 
different ribbon structures, size or ink formulas. 
Maximum weld strength is also affected by the quantity of tensioning, or 
total tension force. Too much tension can be as detrimental to achieving 
optimum weld strength as no tensioning whatsoever. Further, the amount of 
tension force necessary to impart the maximum strength weld in a ribbon 
varies greatly from ribbon composition to ribbon composition. This 
variation occurs as a result of variations in the ribbon material, and as 
a result of variations in the composition of the ink which is often 
preloaded into the ribbon prior to the welding process. 
Different ribbon materials will contain different amounts of nylon, or 
different grades of nylon, which react differently to the ultrasonic 
welding process. Likewise, there may be as many as two thousand 
compositions of ink which may be used with cartridge ribbons. Therefore, 
the combinations of ribbon and ink result in a great variation of ribbon 
welding properties. The proper welding tension for each ribbon or ribbon 
and ink combination is usually determined by trial and error, by welding 
the ribbon at different tensions and then testing the weld strength to 
obtain an optimum weld strength tension. However, as the tension imparted 
during the welding operation is in large part based upon a given 
operator's feel for tension, the optimum tension is commonly not readily 
reproducible from operator to operator, and each operator must determine 
the feel required to impart the optimum tension. Further, as the 
operator's shift progresses, or when the operator resumes operation after 
a break or day or days off from the operation, the requisite feel may 
change leading to non-optimum welding tension. 
Thus, it is apparent that it would be advantageous to develop a method and 
apparatus for controlling ribbon tension during welding which is 
independent of the operator's perception of the proper tension. 
SUMMARY OF THE INVENTION 
Accordingly, there is provided herein a method and apparatus for adjoining 
the ends of a ribbon to form a continuous loop of ribbon within a printer 
ribbon cartridge. The apparatus of the present invention comprises a 
welding fixture which facilitates a precision welding process whereby the 
two ends of the ribbon are adjoined. The welding fixture includes a plate 
for supporting portions of the fixture, guide means for use in precisely 
positioning the ribbon ends in a crisscross arrangement, clamping means 
which automatically clamps the ribbon to the plate, a tensioning means for 
tensioning the ribbon to a preselected value and a cutting means which 
precisely cuts the welded ribbon in an operation separate and distinct 
from the welding operation. 
The guide means includes four pairs of guide bars positioned on the fixture 
so as to define crisscrossed alignment paths. The width of the spacing 
between the bars of any one pair is quickly and easily adjusted by a left 
and right lead screw mechanism supporting the bars. The guide means 
thereby provides a precision ribbon alignment guide and is easily adjusted 
for various widths of ribbons. 
The clamping means includes a ribbon clamp and a ribbon clamp switch near 
each left side pair of guide bars. The ribbon clamp switches are 
positioned along the centerlines of the alignment paths, so that when one 
length of ribbon is held by the operator in two hands along one alignment 
path, the pertinent ribbon clamp switch is directly beneath the operator's 
left hand. The clamp switches can therefore easily be depressed while the 
ribbon end is held tautly along the alignment path. 
The tensioning means includes a tensioning slide which supplies a force to 
one of the clamp means attached to each of the two ribbons. To supply 
tension, the slide is attached to a double ended air bearing piston which 
is mounted at one end to the welding fixture. Air, or other pressure 
media, are supplied to the tension side of the piston to impart a 
preselected force through the clamp means to the ribbon to cause the 
proper tensioning. 
When the clamp switches are depressed, the control system of the welding 
fixture causes a ribbon clamp to rotate into position above the ribbon and 
then drop directly onto the ribbon, clamping it against the plate below. 
The clamping means thus provides an effective apparatus for securing the 
ribbon ends into the alignment means. 
After the ribbon ends have been clamped at four corners into the alignment 
means, the tension slide actuates to impart a preselected tension on each 
ribbon end, and the operator actuates a welder apparatus which performs a 
welding operation. During the welding operation, a welder horn is lowered 
into contact with the crisscrossed ribbon ends. A welding anvil, having an 
upper land surface with a width of approximately 0.010 to 0.020 inch and a 
length of an inch or more, supports the ribbon ends at their crossing 
point from the lower side thereof. The welder horn presses the ribbon ends 
against the welding anvil and ultrasonically vibrates the ribbon material, 
thereby heating it and fusing it along a line conforming substantially to 
the dimensions of the land surface of the welding anvil. The ribbon ends 
are not severed by the welder horn. Hence, the welder horn never contacts 
the welding anvil. The welding fixture includes a separate cutter 
mechanism for performing a precision cutting operation. 
The cutter mechanism includes a lower cutting blade supported on the plate 
below the ribbon, a cutter housing pivotally supported above the ribbon, 
an upper cutting blade attached to the cutter housing, and means for 
pivoting the upper cutting blade into position adjacent to the lower 
cutting blade. The cutter mechanism includes a clamping surface which 
holds the ribbon firmly in position against lower cutting blade during the 
cutting operation. Lower cutting blade is formed from an upper area of 
first welding anvil, conformed to form a cutting surface. After the 
welding operation, the pivoting means causes the cutter housing to move 
from an upper position to a lower position adjacent to the welded ribbon 
and causes the upper and lower cutting blades to sever the ribbon 
precisely along a predetermined path within the bead. The cutter mechanism 
thereby improves the strength of welds by precisely controlling the 
position of the cut along the weld bead. The cutter mechanism also 
diminishes wear on the welder apparatus, and its attendant expense, by 
separating the cutting operation from the welding operation. By separating 
the cutting means from the welding means the energy values of ultrasonic 
welding may be adjusted between the first and second weld operations. 
The welding fixture also includes a pair of arm assemblies for manipulating 
the ribbon ends. Each assembly includes an arm which is pivotally 
supported on the fixture, a thumb at the end of each arm, and a finger 
which pivotally closes against the thumb for grasping therebetween a 
ribbon end. A first arm assembly, known herein as the right arm assembly, 
is arranged for disposing of the ribbon ends severed during the cutting 
operation. A second arm assembly, or left arm assembly, is arranged to 
rotate a ribbon end 180 degrees to remove therefrom a twist and straighten 
the welded ribbon into a straight line. Both arm assemblies operate 
automatically in response to a control system. 
After the cutting operation and after the left arm assembly has 
straightened the ribbon, a second weld or ironing operation is performed. 
During the second weld operation, the welding anvil is replaced with an 
ironing anvil, which has an upper land surface with a width substantially 
greater than that of the land surface of the welding anvil. With the 
ironing anvil positioned beneath the welded ribbon, the welding apparatus 
is lowered into contact with the ribbon for a second time and the ribbon 
is again ultrasonically heated. The weld bead formed during the first 
welding operation is flattened and widened during the ironing operation. 
As the microprocessor controller may be preprogrammed to control the 
intensity and duration of welding, the second weld parameters may be 
selected independent of the first weld parameters. 
The welding fixture is controlled, in substantial part, by a pneumatic 
control system. The control system includes a source of pressurized fluid, 
a plurality of microprocessor controlled valves, and a plurality of 
pneumatic cylinders. Each cylinder provides the means by which portions of 
the fixture, such as clamps, arms, and fingers are caused to move. After 
all operations have been completed, the fixture unclamps the ribbon and 
returns all apparatus to its starting positions. Each of the mechanical 
steps is controlled by a microprocessor controller. 
The present invention is the first welding fixture to provide the industry 
with all the features necessary to produce consistently a high quality 
weld in a continuous loop ribbon. Precise control of the ribbon end 
tension during the welding operation provides consistent high strength 
continuous ribbons. Precise alignment of ribbon for the majority of ribbon 
sizes eliminates one problem and results in continuous loop ribbons which 
are consistently straight in the region of the weld. Separating the 
cutting operation from the welding operation substantially reduces wear on 
the welder horn, which never contacts the welding anvil in the present 
invention, and thereby the ribbon manufacturer has reduced the replacement 
costs of worn welder horns, anvils and cutting blades. The use of a 
separate precision cutter mechanism produces weld beads of repeatable, 
consistent, predetermined widths, thereby enabling one to control better 
the strength of the weld. 
These and various other objects and advantages of the invention will become 
readily apparent to those skilled in the art upon reading the following 
detailed description and claims and by referring to the accompanying 
drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
The general operation of a continuous loop welding system is well known in 
the art, and reference is made to the disclosures of U.S. Pat. Nos. 
4,629,530 and 4,935,081, which are expressly incorporated herein as though 
fully set out herein, for further details of the well known operating 
features of these apparatus. The general principles of the present 
invention, as already described, remain unchanged. Where possible, 
portions of the invention described in U.S. Pat. Nos. 4,629,530 and 
4,935,081 will be identified by the reference characters previously used. 
The Basic Process 
FIGS. 1A to 1C and FIGS. 1 to 4 of U.S. Pat. Nos. 4,629,530 and 4,935,081 
disclose the basic process for which the present invention is used. 
Generally, as shown in FIGS. 1 and 2 herein, a welding fixture 100 is 
provided with a v-shaped track 102, a welding anvil 104 and an ironing 
anvil 106. As shown in FIGS. 1A to 1E, a pair of ribbon ends 114, 116 are 
placed, in criss-cross fashion, over the welding anvil 104. Ribbon ends 
114, 116 form the ends of ribbon 112. Ribbon end 116 is folded over at 
fold 128, adjacent welding fixture 100, such that after welding, end 116 
may be folded back over fixture 100 to straighten ribbon 112. The acute 
angle between the two segments of ribbon end, which is bisected by 
v-shaped track 102, is 60.degree.. After the ribbon ends are properly 
positioned, a welder head is lowered adjacent the intersection, and a weld 
bead is placed across the intersection substantially collinear with the 
v-shaped track 102. A cutter then trims the ends of the ribbon, forming a 
flat end 134. One of the ribbons is then folded over to reveal a nub 136, 
which is then flattened over the ironing anvil 106 by a second application 
of the welding horn 170. 
The Welding Fixture 
Referring now to FIGS. 1, 2 and 3, there is shown therein a welding fixture 
100 structured according to the principles of the invention. The welding 
fixture 100 includes a guide and switch plate assembly 150, a cutter 
assembly 152, two ribbon clamp assemblies 154a, b, two ribbon clamp and 
tension assemblies 153c, d, a right arm assembly 158, a left arm assembly 
160 and a track assembly 162. 
Referring briefly to FIG. 1, there is shown a welder apparatus 164 with the 
welding fixture 100 positioned thereon. The welding apparatus 164 includes 
a welding horn 170 extending downwardly toward fixture 100 from a welder 
housing 167 on welder piston 168. Welder housing 167 includes a pair of 
actuation switches 171a, 171b, which are simultaneously actuated in 
push-button fashion to initiate the downward stroke of the welder piston 
168. A micrometer 173 (FIG. 3) is provided for fine adjustment of welder 
piston travel. The micrometer 173 actuates a bar to engage a second bar on 
welder piston 168, to limit the downward stroke of horn 180. 
Guide and Switch Plate Assembly 
Referring now to FIG. 2, there is shown a switch plate 180 adjustably 
supported on four columns (not shown). The columns support the switch 
plate 180 during welding and trimming operations. Switch plate 180 further 
includes guide plate 186 disposed thereon. The end faces 184 of the two 
left hand corners of the guide plate 186 are bevelled, and the end faces 
185 of the two right hand corners of guide plate 186 are configured with a 
more severe, or deeper, bevel, leaving the right end 196 of the guide 
plate with a bottle neck configuration 191. The guide plate further 
includes, disposed down the center of the lengthwise direction thereof, 
V-shaped cut or track 102. The guide plate includes level adjusting 
apparatus (not shown) to level the guide plate during the welding, cutting 
and flattening operations. 
Referring still to FIG. 2, an adjustment channel 190a-d is machined into 
the upper surface of the guide plate 186 in each of the four corners 
thereof. Front adjustment channels 190a, 190d extend from a front 
lengthwise face 192 of the guide plate 186 toward, but not intersecting, 
right and left ends 196, 198, respectively. The centerlines of the front 
adjustment channels 190a, 190d form acute angles of 60 degrees with 
respect to the plane of the front face 192 of guide plate 186. The 
orientation of the two rear adjustment channels 190b, 190c relative to the 
rear lengthwise face 194 of the guide plate 186 is symmetric with respect 
to the centerline of the V-shaped track 102 to the two front adjustment 
channels 190a, 190d. 
There is included within each adjustment channel 190 a left and right lead 
screw adjustment mechanism 200a-d. The lead screw mechanism 200 of each 
adjustment channel 190 is identical, so that description of a single 
mechanism 200 shall suffice as a description of all four mechanisms. Each 
mechanism 200 includes a shaft 202 rotatably supported along the 
centerline of the adjustment channel 190 by a support housing 204. The 
support housing 204 is affixed to the upper surface of the guide plate 186 
by means of screws. The shaft 202 includes opposing left and right threads 
206a, 206b disposed symmetrically about a center alignment space 208. A 
pair of guide bars 210a, 210b include opposing threaded bores therethrough 
for receiving the opposing left and right threads 206a, 206b, 
respectively, of the threaded shaft 202. The guide bars 210a, 210b extend 
generally perpendicularly from the shaft 202 toward the center of the 
guide plate 186. Rotation of the shaft 202 causes simultaneous movement of 
the guide bars 210a, 210b either toward or away from one another, 
depending upon the direction of rotation of the shaft 202. 
The position of the center alignment point 208 within the adjustment 
channel 190d, as determined by the position at which the support housing 
204 is attached to the guide plate 186, is selected so that a 
perpendicular projection from the shaft 202 through the center of the 
space 208 passes through a corresponding center point of a space 208 on a 
corresponding shaft 202 within the opposing adjustment channel 190b. The 
left and right lead screw mechanisms 200 are similarly positioned within 
the second opposing pair of adjustment channels 190a, 190b. The guide bars 
210a, 210b from each of the four lead screw mechanisms 200 thereby define 
with precision the alignment path of the ribbon which is to be welded. 
Rotation of the shaft 202 permits adjustment of the width of the alignment 
path whereby the operator may quickly and precisely alter the set-up of 
the welding fixture 100. 
The Ribbon Clamp Assemblies 
Referring still FIG. 2, there is depicted therein two ribbon clamps 300a, 
300b in fully open position and two corresponding button-actuated clamp 
switches 302a, 302b. The ribbon clamps 300a, 300b are positioned in each 
of the two bevelled end faces 184 of the guide plate 185 so as to assume a 
position in contact with the guide plate 186, adjacent and parallel to a 
corresponding adjustment channel 190a, 190b, when actuated. The clamp 
switch 302a is positioned on and within the switch plate 180 near the 
corresponding ribbon clamp 300a, and is centered on a line which 
intersects the center point of the center spaces 208 of the shafts 202 
affixed within the alignment channels 190a, 190c. The clamp switch 302a is 
thereby collinear and is precisely aligned with the centerline of the 
ribbon placed in the fixture for welding. The clamp switch 302b is 
similarly arranged. When an operator actuates a clamp switch 302 by 
depressing it, the corresponding ribbon clamp 300 rotates through an arc 
of approximately 90 degrees and drops downward into contact with the upper 
surface of the guide plate 186 to grip the ribbon therebetween. 
Referring still to FIG. 2, there is also depicted therein two ribbon 
tension clamps 300c, 300d. The ribbon tension clamps 300c, 300d are 
positioned in each of the two bevelled end faces 185 of the guide plate 
186 adjacent necked down portion 191 so as to assume a position in contact 
with the guide plate 186, adjacent and parallel to a corresponding 
adjustment channel 190c, 190d, when actuated. When an operator actuates a 
clamp switch 302 by depressing it a second time after actuating clamp 
300a, ribbon tension clamp 300c rotates through an arc of approximately 90 
degrees and drops downward into contact with the upper surface of the 
guide plate 186 to grip the ribbon therebetween. Likewise, a second 
depression of clamp switch 302b causes ribbon tension clamp 300d to rotate 
through an arc of approximately 100.degree. and drop downward into contact 
with the upper surface of the guide plate 186 to grip the ribbon 
therebetween. 
The bevelled end faces 184, 185, at the corners of the guide plate 186 
enable the operator to maintain the ribbon in alignment during the 
clamping process. Were the end faces of the corners not bevelled along a 
line parallel to the adjacent lead screw mechanism 200, the corner edges 
of the guide plate 186 would tend to bias the ribbon out of alignment as 
the ribbon clamp switches 302 are being depressed. Hence, the bevelled 
corners are an essential feature of the present invention. 
Referring now to FIGS. 5 and 6, the right front ribbon clamp and tension 
assembly 153d is depicted in elevation from the rear side. Ribbon clamp 
and tension assembly 153 includes ribbon tension clamp 300d mounted 
therein. Ribbon tension clamp 300d is mounted within slide 301 and 
includes a shaft 306, a gripper mechanism 308 and a shaft guide mechanism 
310. A pneumatic cylinder 304 is positioned on the end 307 of shaft 306 
terminating within slide 301. Slide 301 is a generally rectangular portion 
of metal, the dimensions and function of which will be set out in greater 
detail in the section entitled "The Ribbon Clamp and Tensioning Assembly". 
Slide 301 includes a through bore 303 terminating at the lower face 305 of 
slide 301 in a threaded counterbore 309. The cylinder 304 is affixed by 
means such as a threaded engagement into counterbore 309. End 307 of shaft 
306 includes an enlarged diametrical portion having a threaded bore (not 
shown) therein. Cylinder 304 includes a piston rod 313 having a threaded 
end thereon, which threadingly engages the threaded bore in end 307 of 
shaft 306. The upper end of the shaft 306 extends above slide 301, to a 
point approximately 1.0 inch beyond the upper surface of the guide plate 
186. 
Referring now to FIGS. 4, 5 and 6, the gripper mechanism 308 includes a 
horizontal support bar 316 extending generally perpendicularly from and 
rigidly affixed to the upper end of the shaft 306. FIG. 5 depicts the 
gripper mechanism 308 in the disengaged position, whereas the gripper 
mechanism 308 is shown in the engaged position in FIG. 6. A flexible pad 
318, for example, a block of rubber, is rigidly attached to the lower 
surface of the horizontal support bar 316 for adhesively gripping the 
ribbon against the upper surface of the guide plate 186. A second pad, 
320, is disposed on the upper surface of slide 301 in alignment with the 
location with pad 318 when support bar 316 is actuated downward to pinch 
the ribbon between pads 318 and 320. 
The lower end 307 of the shaft 306 includes a pair of spiral channels 324 
arranged so as to be constantly 180 degrees opposed. Slide 301 includes 
therethrough a crossbore 317 which intersects bore 303 within slide 301. 
The longitudinal length of spiral channel 324 is configured such that when 
shaft 306 is fully inserted into bore 303, the upper terminus 319 thereof 
is disposed adjacent the intersection of crossbore 317 with bore 303. 
Channels 324 include a short vertical drop, for example 0.5 inch, across a 
spiral arc of approximately 90 degrees and end with a substantially 
vertical span, for example 0.5 inch, to a point near end 307. Crossbore 
317 includes a minor diameter portion 331 therein projecting approximately 
one inch from either side of the intersection of crossbore 317 with bore 
303. Minor diameter portion 331 is threaded, and a ball 321, spring 323 
and plug 325 are disposed in each of portions 319 Ball 321 is disposed at 
the intersection of bore 303 and crossbore 317, and spring 323 is biased 
against ball and held in place by plug 325 threaded into the wall of minor 
diameter portion 319. Vertical motion of the shaft 306 causes balls 321 to 
engage the inside walls of the two spiral channels 324 and thereby rotate 
the shaft 306 on its vertical axis. The final vertical span of the spiral 
channels 324 within shaft 306 insures that the ribbon is gripped against 
the guide plate 186 from directly above the ribbon, so that the alignment 
of the ribbon is not disturbed. The relative dimensions of the apparatus 
comprising the ribbon tensioning clamp 300 are arranged so that the 
flexible pad 318 firmly engages the pad 320 on upper surface of slide 301 
before downward vertical motion of the shaft 306 is obstructed by contact 
of shaft 306 with the upper end of cylinder 304. 
The cylinder 304 further includes a pair of fluid ports 328a, b (328b not 
shown) for delivering and exhausting pressurized fluid from the interior 
of the cylinder 304, so as to generate vertical motion of the shaft 306. 
Each of ribbon clamps 300a, b are similarly actuated by a pneumatic 
cylinder which supplies vertical actuation of the clamp to grip the 
ribbon. However, unlike ribbon tension clamps 300c and 300d, the shafts 
306 supporting ribbon clamps 300a, b each include a cross pin projecting 
therethrough which is received in an groove in a bore located in a 
secondary guide mechanism located under switch plate 180. For details of 
this assembly, which is well known in the art, reference should be made to 
U.S. Pat. No. 4,629,530, Col. 14, line 55 to col. 15, line 64. 
The actuation of ribbon clamps 300 a, b and ribbon tension clamps 300c, d 
are controlled by depression of the clamp switches 302 a, b. Each clamp 
switch 302a, b is a manually actuated microswitch, such as a microswitch 
manufactured by Micro Switch. Actuation of switch 302a transmits a signal 
to the microprocessor controller unit, which in turn sends a signal to a 
solenoid controlling the pressure feed lines on the pistons controlling 
ribbon clamps 300a,b and ribbon tension clamps 300c, d to actuate the 
clamp 300a-d to grip the ribbon. The controller is preprogrammed, or 
sequenced, to cause the ribbon tension clamp 300c or 300d to actuate to 
grip ribbon end before the corresponding ribbon clamp 300a or 300b engages 
the ribbon end. This sequence is further defined in the section entitled 
"The Operating Sequence". 
The Right Arm Assembly 
FIGS. 2 and 3 depict various views of the right arm assembly 158 in its 
inward position. FIG. 2 shows a top view of the switch plate 180 with the 
right arm assembly 158 positioned on the right side thereof. FIG. 3 
depicts the right arm assembly 158 in perspective. Referring to FIGS. 2 
and 3, the right arm assembly comprises an elongated arm 350, a thumb 352, 
a finger 354, a rotating mechanism, and a grasping mechanism 358. 
The right arm assembly 158 is designated to rotate through a 180-degree arc 
between the inward horizontal position depicted in FIGS. 2 and 3 and an 
outward horizontal position where the arm 350 rests on the guide plate 186 
in front of the right rear corner thereof. The right arm assembly 158 
performs the service of grasping the waste ends of the ribbon and removing 
them from the fixture 100 after they have been severed from the welded 
ribbon. 
The elongated arm 350 comprises a generally linear metallic element having 
a length sufficient to enable the thumb 352 and the finger 354, when 
closed, to grasp the left ribbon end at the right rear side of the guide 
plate 186. The outwardmost end of the elongated arm 350 is machined to 
define the thumb 352. Such machining may, for example include a reduction 
of the cross-sectional area of the element comprising the arm 350 for a 
short length, for example, 1.5 inches, to define the thumb 352. The inner 
surface of the thumb 352 is preferably machined to include a plurality of 
serrated edges or teeth 360 for the purpose of facilitating a secure grip 
on the ribbon. 
The finger 354 similarly is formed of a machined metallic element having a 
cross section substantially similar to that of the thumb 352. The finger 
354 includes teeth 362 arranged to mesh with the opposing teeth 360 of the 
thumb 352. The inner end of the finger 354 is pivotally attached to the 
arm at 350 at a point 364 near the thumb 352 and is also pivotally 
attached to a finger closure extension bar 366, which is coupled to a 
cylinder shaft so as to enable the finger 354 to rotate into the closed 
position in response to motion by the extension bar 366 along a single 
dimension. The details of the structure of the rotating mechanism and the 
operation of the right arm assembly 158 are well known to those skilled in 
the art, and such structure and operation is also disclosed in U.S. Pat. 
No. 4,629,530, col. 16, line 38 to col. 18, line 19, which disclosure had 
been expressly incorporated herein by reference. 
Control of the right arm assembly is controlled by the microprocessor 
controller 120. After the cutter assembly trims the waste ribbon, as will 
be detailed further herein, the microprocessor controller sends a signal 
to a finger control solenoid to cause the small cylinder controlling the 
finger 354 to cause the finger 354 to engage the trim between thumb 352 
and finger 354. The microprocessor controller then signals an arm solenoid 
to energize the arm piston to swing the arm 350, and attached trim, 180; 
and then a signal is sent causing the finger piston to vent and bias the 
finger 354 open to release the trim. The microprocessor controller than 
signals the arm piston to return the arm to the position shown in FIG. 3. 
After the right arm 158 has carried the waste ribbon away from the cutter, 
a vacuum, or transvector mechanism, located at the far right of the unit, 
pulls the scrap away. 
The Left Arm Assembly 
The left arm assembly 160 is depicted in FIGS. 2 and 3. FIG. 2 is a top 
view of a portion of the welding fixture 100 showing the left arm assembly 
160 affixed to the switch plate 180 at the left end face 198 of the guide 
plate 186. FIG. 3 depicts the Welding fixture 100 with left arm assembly 
160 thereon in perspective. The left arm assembly 160 is substantially 
identical in pertinent part to the right arm assembly 158. The apparatus 
of the left arm assembly 160 which is substantially identical to 
corresponding apparatus of the right arm assembly 158 is identified in 
FIGS. 2 and 3 with a primed reference character of the same number as the 
corresponding right arm apparatus. The differences between the right and 
left arm assemblies 158, 160 are described below. 
Because the left arm assembly 160 serves a purpose different from that of 
the right arm assembly 158, the left arm assembly 160 is oriented at 90 
degrees with respect to the orientation of the right arm assembly 158. The 
axial centerline of the arm support housing 375' is coplaner with the 
centerline of the V-shaped track 102 within the guide plate 186. The left 
arm assembly 160 includes a shortened arm 400 having a length sufficient 
to place the thumb 352' and the finger 354' within the path of the ribbon 
at the front left corner or the rear left corner of the guide plate 186, 
depending upon the rotational position of the arm 400. The structure of 
the left arm assembly is well known in the art, and is described in U.S. 
Pat. No. 4,629,530 col. 18, line 45 to col 19, line 24, which disclosure 
has been expressly incorporated herein by reference. 
The Track Assembly 
The track assembly 162 is shown in FIGS. 2 and 3. The V-shaped track 102 
includes an upper surface which has been machined and ground to a smooth 
finish so as to enable precise alignment of the welding anvil 104 and the 
ironing anvil 106 and limited friction in movement of the same along the 
track surface. 
Referring now to FIG. 2, the welding anvil 104 includes a surface 108 
against which the ribbons are welded and clamped and a cutting edge for 
severing the ribbons along the weld bead. The welding surface includes a 
land surface and a cutting edge which cooperates with an upper cutting 
blade (described below in the section entitled "The Cutter Assembly") in 
scissor or rotating blade fashion or guillotine action to sever the welded 
ribbon along the weld bead. The lower surfaces of the welding anvil 104 
generally define a V-shaped cross section which conforms precisely to the 
cross-sectional dimension of the V-shaped track 102. The structure and 
operation of the welding anvil is well known in the art, and described in 
U.S. Pat. No. 4,629,530, col. 19 line 25 to col. 20, line 19, which 
disclosure has been expressly incorporated herein by reference. 
The second welding, or ironing, anvil 106 includes a generally horizontal 
upper ironing surface 110 against which the weld bead may be flattened 
during the second welding, or ironing, operation. The lower surface of the 
ironing anvil 106 is machined to a cross section which conforms 
substantially to the dimensions of V-shaped track 102. The second anvil 
106 is preferably located slightly lower than first anvil 104, to permit a 
slightly greater space between horn 180 and anvil 106 during the ironing 
operation. The operation of the ironing anvil, and interaction thereof 
with the welding anvil and the positioning thereof during the welding 
operations is well known in the art, and is disclosed in U.S. Pat. No. 
4,629,530 col. 19, line 25 to col. 21, line 28. 
The Cutter Assembly 
The cutter assembly 152 is disclosed in FIG. 3. FIG. 3 depicts a 
perspective view of the welding fixture from the left front side thereof. 
Referring briefly to FIG. 3, the cutter assembly 152 includes a support arm 
602, a cutter mechanism 604, and a pneumatic cylinder (not shown) which 
actuates the cutter mechanism. 
The operation of the cutter mechanism 604 and its cooperation with the 
welding anvil 104 to sever the ribbon precisely along a predetermined path 
within the weld bead is well known in the art, and is disclosed in U.S. 
Pat. No. 4,629,530, col 21, line 30 to col. 24, line 33. 
The Ribbon Clamp and Tensioning Assembly 
FIGS. 2 and 4 to 11 disclose the structure of the ribbon clamp and 
tensioning assemblies 153c,d. FIG. 2 shows the mounting location of 
assemblies 153c,d on the switch plate 180. FIG. 4 shows a sectional view 
of assembly 153d along a line 4--4 in FIG. 2. FIG. 5 is a rear view, 
partially in cutaway, of the assembly 153d. FIG. 6 is a front view, and 
FIG. 7 is a bottom view of the assembly 153d, FIG. 8 is a bottom view of 
the assembly 153d. FIGS. 9 to 11 are cutaway and sectional views of the 
assembly 153d, showing details of operation. 
Referring now to FIGS. 1B 2 and 4, ribbon clamp and tensioning assembly 
153d is mounted to switch plate 180 and positioned on switch plate 180 
near alignment channel 190d, such that the engagement of gripper mechanism 
308 with the ribbon end 114 is in alignment with a line which intersects 
the center point of the center spaces 208 of the shafts 202 affixed within 
the alignment channels 190b, 190d. Likewise, clamp 300c is aligned with 
the line which intersects the center of the shafts 202 in slots 190a and 
190c. Switch plate 180 includes, along the right side thereof, slots 620, 
621 therein which extend from the right end thereof inward of plate 180 
and from the front and rear corners thereof inward at an approximate 
60.degree. angle. Slots 620, 621 are located to permit attachment of 
ribbon clamp and tensioning assemblies 153c,d with clamps 300c, d thereon 
in proper alignment to clamp the ribbon through the center of slots 
190a-d. 
Ribbon clamp and tensioning assembly 153d includes slide 301 slidingly 
engaged on stationary member 622, piston carrier 624, tension piston 626 
(FIGS. 7 and 8), reset piston assembly 628 and tension position lock 
piston 630 (FIG. 13). 
Referring now to FIGS. 4 and 10 stationary member 622 is a generally 
L-shaped member in cross section, having flank 632 formed from the longer 
portion of the L and a mounting flange 634 forming the leg of the L. 
Mounting flange 634 includes a plurality of countersunk bores 636 
therethrough, for receiving bolts 638 to be received within threaded holes 
640 in plate 180 for mounting ribbon clamp and tensioning assembly 153c or 
153d thereto. Flank 632 includes bearing race support 642 extending 
thereon, which is a raised portion thereof having a generally rectangular 
cross section extending therefrom opposite flank 632. Flange 634 includes 
an outer face 644 which is an outer extension of flank substantially 
parallel thereto, and opposed upper and lower bearing faces 646, 648 
disposed between flank 632 and face 644. Straight roller bearings 650 are 
disposed on bearing faces 646, 648. Inner face 652 of stationary member 
622 is a flat surface extending from lower edge 654 thereof to the lower 
surface of flange 634, which includes piston reset extension 662 thereon 
formed as a partial downward extension of flank 632 below lower edge 654 
and lock piston bore 656 (FIG. 13) projecting therethrough adjacent lower 
edge 654. Piston reset extension 662 includes reset piston slot 658 
disposed therethrough in outer edge 664 adjacent lower edge 654, and reset 
finger slot 660 projecting upward therein from lower edge 654. Reset 
finger slot 660 is a blind slot, exposed only to lower edge 654 and inner 
face 652. 
Slide 301 is a generally C-shaped section, having outer slide housing 670 
terminating in inwardly projecting opposed upper and lower bearing support 
arms 672, 674 separated by inner slide face 678. Straight bearings 680 are 
disposed on bearing support arms 672, 674 and engage with and slide over 
roller bearings 650 disposed on bearing faces 646, 648 of stationary 
member 622. Upper surface 649 of slide 301 each include a pair of threaded 
holes 647 FIG. 8 therein. A ribbon alignment plate 651, which forms the 
upper surface of ribbon clamp and tensioning assembly 153d, is bolted to 
upper surface 649 of slide 301 to receive ribbon during the welding, 
cutting and flattening operations. 
Referring now to FIGS. 4 7, 8, 10 and 11, tensioning piston 626 includes 
piston housing 682 rigidly attached to piston carrier 624, and a piston 
rod 684 projecting therefrom and terminating in threaded stud 686. Piston 
carrier 624 includes mounting bore 688 therein through which piston 
housing 682 projects and is secured. Piston carrier 624 is a generally 
flat plate having an angular flange 690 having mounting bore 688 
therethrough, and is bolted to stationary member 622 to cover reset finger 
slot 660 and reset piston slot 658. Piston rod 684 projects through a bore 
in a flange 692 in slide mount 691, and is affixed thereto by nuts 694 
threaded on the stud 686 on either side of flange 692. Flange 692 is 
likewise connected to the lower surface 645 of slide 301 through bolts 
inserted through holes in flange 690 and received within threaded holes 
647. Actuation of piston rod 684 in housing 682 will cause slide 301 to 
linearly actuate on stationary member 622 to tension the ribbon under the 
welder. 
Referring briefly to FIG. 11, tensioning piston 626 includes piston housing 
682 and a piston rod 684 projecting therefrom and terminating in threaded 
stud 686. Tensioning piston is a double sided air bearing piston, having a 
double sided right cylindrical piston 683 disposed within a right 
cylindrical piston bore 685. Bore 685 terminates at outer end 687 in a 
cover 689, which is secured in place with a snap ring 711 recessed into a 
snap ring groove 693 in bore 685. At piston inner end 695, housing 682 
includes a threaded nipple extension 698, having a rod bore 699 
therethrough. Piston rod 684 extends through rod bore 699. Air is supplied 
to tensioning piston 626 through tension port 681 and compression port 
697. Tension port 681 is disposed through housing 682 to inject 
pressurized air to the front of piston 683 to bias piston away from the 
welder, thereby tensioning the ribbon. Compression port 697 is disposed on 
housing 682 to access the rear side of piston 683, to bias piston toward 
the welder thereby relieving compression on the ribbon. Piston bore 685 
has a diameter of preferably two to three thousandths greater than the 
outer diameter of straight sided cylindrical piston 683. Further, rod bore 
699 is approximately five thousandths larger in diameter than rod 684, 
leaving a clearance between adjoining sliding parts of approximately two 
and one half thousandths of an inch. When the piston is energized with air 
through ports 681, 683, the air bleeds through this clearance forming a 
supporting cushion of air between piston 683 and bore 685 and between rod 
684 and bore 699. This structure eliminates hysteresis in the piston which 
would occur with seals. 
Referring now to FIGS. 6 and 13, tension position lock piston 630 is 
located on ribbon clamp and tensioning assembly 153d to lock slide 301 to 
stationary member 622 during welding. Referring to FIG. 13, lock piston 
630 is located on inner face 652 of stationary member 622 over lock piston 
bore 656. Lock piston 630 includes a lock piston housing 631 having a 
reciprocable piston (not shown) disposed therein, an air port 635 disposed 
therethrough to inject air behind piston (not shown) to actuate piston 630 
to lock ribbon clamp and tensioning assembly 153d during welding 
operations. Air port 635 is threaded (not shown) to attach a fitting 637 
to receive an air hose 639 for air supply. To lock stationary member 622 
to slide 301, the piston includes a lock rod 633 disposed thereon and 
extending outward housing 631 into piston bore 656 and includes a rubber 
bumper 641 disposed on the terminal end thereof outward housing 631. To 
lock slide 301 to stationary member 622, air is supplied to air port 635 
thereby actuating the piston and rod 633 against slide 301 such that 
bumper 641 interferingly engages slide 301 adjacent bearings 650 (FIG. 4) 
and lower bearing support arm 672. Piston 631 is spring biased such that 
when air is not applied thereto, bumper 641 retracts from slide 301 into 
piston bore 656 permitting slide 301 to actuate freely with respect to 
stationary member 622. 
The tensioning piston reset assembly 628 is shown in FIGS. 4, 9 and 10. 
FIG. 4 shows a sectional view of the ribbon clamp and tensioning assembly 
153d showing the reset piston slot 658. FIGS. 9 and 10 show the actuation 
of the reset piston assembly 628 used to center tensioning piston 626 
(FIG. 7). Referring briefly to FIGS. 9 and 10, piston reset assembly 628 
includes a spring loaded piston housing 619 having a finger rod 621 
extending therefrom inward of reset finger slot 660. Housing 619 includes 
a threaded nipple end 623 which is threaded into a mounting plate 625 
having a plurality of countersunk bores 627 (only one shown) therethrough. 
Lower edge 654 of piston carrier 624 has a plurality of corresponding 
tapped holes 629 (only one shown) therein, which receive screws 631 to 
secure mounting plate 625 thereto and thus to stationary member 622 such 
that finger rod 621 extends into finger slot 660. Reset finger 601 is 
disposed against the terminal end of finger rod 608 and in finger slot 
660. 
Referring now to FIGS. 4, 9 and 10, finger slot 660 has a major portion 603 
extending from lower edge of stationary member 622 inward beyond the upper 
edge 605 of reset piston slot 658 and bounded by an outer wall 607 which 
is intersected by reset piston slot 658 and an inner wall 609 extending 
substantially parallel thereto, and a minor portion 611 located inward of 
major portion 603. Minor portion 611 is approximately one half of the 
width of major portion 603, and share inner wall 607 therewith. Minor 
portion 611 terminates in radial wall 613 inward of stationary member 622 
from major portion 603. Finger 601 is conformed to match the profile of 
finger slot 660, and includes major finger portion 615 attached to finger 
rod 621 and minor finger portion 617 extending inward stationary member 
622 to be selectively received in minor portion 611. Finger 601 further 
includes bearing wall 606 disposed thereon adjacent to reset piston slot 
658 and a secondary bearing face 618 adjacent to the intersection of minor 
finger portion 601a and major finger portion 601b opposite inner wall 607 
A pin 701 is disposed in slide 301, projecting from lower bearing wall 672 
to be received within reset piston slot 658. After a welding cycle is 
completed, tensioning piston 626 is actuated such that piston is fully 
retracted away from the welder, and pin 701 is resultingly retracted from 
reset piston slot 658. Reset piston 628 is then actuated, forcing rod 621 
against spring bias within piston housing 619 to actuate finger 601 upward 
into finger slot 660 bringing bearing wall 606 over and into blocking 
position with reset piston slot 658. Tensioning piston 626 is then 
actuated inward toward the welder, bringing pin 701 against bearing wall 
606. The bearing wall 606 is located with respect to slide 301 and pin 701 
such that when pin 701 abuts against bearing wall, slide is located at the 
center of its lateral travel limits. This position is shown in FIG. 9. 
To limit slide travel, secondary bearing wall 618 is positioned into 
alignment with pin 701 travel by releasing the air pressure from piston 
628, thereby permitting the spring therein to actuate the finger 601 
downward and thus placing secondary bearing wall 618 in position to 
receive pin 701 upon inward overtravel of slide 601. This position is 
shown in FIG. 10. 
The Pneumatic Schematic 
FIG. 12 shows the pneumatic schematic for the ribbon welder. Each of the 
pneumatic cylinders used to control or actuate the equipment is controlled 
through a microprocessor controlled solenoid valve. The microprocessor 
sends a digital signal to each of the various control solenoids, causing 
the solenoid to actuate and perform a manufacturing function. 
Referring now to FIG. 1, 2, 3, 5 and 12, pneumatic system 700 is sourced 
from a pneumatic pressure source 702 which supplies air at a relatively 
constant pressure to the system 700. The air, or working fluid, is passed 
through a filter 704 to filter out possible impurities which would 
potentially cause the equipment to jam or fail. The filtered air is then 
ported to a filtered supply line 706 which supplies a horn regulator valve 
708, a transvector valve 710 and a main manifold supply line 712. Supply 
line 712 supplies regulated dried air to left distribution manifold 714 
and right distribution manifold 716. The air is dried in a mist separator 
718 which is located upstream of the manifolds 714, 716, and a regulator 
valve 720 disposed between mist separator 718 and manifolds 714, 716. 
Regulator 720 is adjustable to supply air to manifolds 714, 716 at 
pressures of between 0 and 60 p.s.i. 
Right distribution manifold 716 supplies the working air to the tensioning 
locks and centering cylinders, and the door cylinders. The tensioning 
pistons 626 are supplied through a secondary manifold E 722. The remaining 
right distribution manifold also supplies a Manifold D 724 which supplies 
the reset cylinders, lock cylinders and door cylinders. The left manifold 
supplies the remaining pneumatic components through manifolds A, B and C, 
726, 728 and 730. 
Manifold E 722 is ported to supply rear tension cylinder selenoid 145 and 
front tension cylinder selenoid 147. Solenoids 145 and 147 control the 
transmission of presssurized air to either side of the tensioning pistons 
626, as to to control the initiation and duration of the tensioning of 
ribbon portions 114, 116 (FIG. 1A). Manifold E 722 further includes a 
digital regulator assembly 721 which is controllable to finely control the 
pressure in manifold E and thereby the tensioning pressure in tensioning 
pistons 626. Digital regulator assembly 721 is ported with manifold E such 
that fine pressure regulation only occurs on the tensioning side of 
tensioning piston 626. 
Manifold D 724 supplies door control solenoid 111, rear tension centering 
selenoid 163, front tension centering selenoid 165 and tension cylinder 
lock control solenoid 723. Each of solonoids 111, 163, 165 and 723 control 
a corresponding cylinder or piston used to operate the welding sequence. 
Manifold C 726 supplies a winder air stream selenoid 725, cutter control 
selenoid 727 and anvil shift control solenoid 159. Winder air stream 
solenoid controls the air supplied to an optional air or electric motor 
powered winder which may be used to rewind the ribbon into a cartridge. 
Cutter control solenoid 727 controls the cylinder which actuates the 
cutter. Solenoid 159 controls the actuation of anvil cylinder 161 which 
shifts the anvils 104, 106 under the horn 180. 
Manifold B supplies right arm control solenoid 149, right arm thumb control 
solenoid 151, and front and rear tension clamp control solenoids 731, 732. 
Selenoid 149 controls the air pressure supply to the right arm 158 to 
actuate arm 158 between its first position adjacent to the anvils 104 or 
106 and its second position adjacent to the right end of plate 180. 
Solenoid 151 controls the cylinder which opens and closes finger 354 on 
arm 158. Solenoids 731, 732 control pistons 304 which controls the 
position of clamps 300c, d. 
Manifold A 730 supplies pressurized air to clamp control solenoids 141, 
143, and reversing arm and reversing arm thumb control cylinders. 
Solenoids 141, 143 selectively supply air to the cylinders which actuate 
clamps 300a, b between the open and closed positions. Solenoid 153 
controls the supply of air to the left arm 160 to actuate it between its 
first position adjacent to the front of guide plate 186 and its second 
position adjacent to the rear of guide plate 186. Solenoid 155 controls 
the cylinder which actuates thumb 352' between its open and closed 
position. 
Horn regulator valve 708 may be adjusted to control the air pressure on 
horn ram 736 through horn control solenoid 738. Solenoid 738 is 
controllable to move horn 180 between the up position and the lowered 
position for welding. 
Transvector 710 is a vacuum generator which is selectively actuated through 
transvector solenoid 740. Transvector 710 is actuated to pull the scrap 
ribbon after cutting. 
The Operating Sequence 
Referring now to FIGS. 13, 14, 15 and 16, the operating sequence of the 
Continuous loop ribbon welding system is shown. The cold start up 
procedure is shown in FIG. 14. FIGS. 15, 16 and 17 show the operating 
procedure during welding of ribbon ends. 
Referring now to FIGS. 1 through 14, cold start up of the welder requires 
sequencing of various operations to ensure that the welder will 
satisfactorily operate. To initiate operation, the operator depresses palm 
buttons, or actuation switches 171a, b on the right and left hand side of 
the cabinet 105 holding the apparatus, and door comes down over the front 
opening of the cabinet to protect the operator from injury. The door is 
closed by hydraulic door cylinders 107, 109 fed from dual position door 
solenoid 111. Door cylinders 107, 109 are dual ended piston cylinders, and 
door solenoid 111 is actuated by a signal from microprocessor controller 
120 to open or close doors by communicating pressurized air from to either 
side of the door cylinders 107, 109. Once the door is closed, the 
microprocessor controller 120 transmits a signal to the cutter piston to 
move the cutter mechanism 604 up, to close the solenoid supplying the 
winder, to turn the winder air off, the vacuum off, to actuate the 
cylinder controlling finger 354 to open finger 354 on right arm assembly 
150, to open the finger 354 on the left arm assembly 160, to actuate the 
clamp cylinder solenoids 141, 143 to actuate the cylinders controlling the 
ribbon clamps to actuate the ribbon clamps 300a, 300b upward, and actuate 
tensioner solenoids 145, 147 in manifold E 722 to engage pressurized air 
to cylinder 304, so as to generate vertical motion of the shaft 306 and 
move gripper mechanisms 308c and 308d upward. The microprocessor 
controller 120 sends the appropriate signal to each solenoid to cause the 
appropriate cylinder to actuate in the proper position to place the 
componentry in the above referenced positions. However, as each component 
is controlled by cylinders and solenoids, if a component is already in the 
cold reset position, the signal will not effect its position. Once the 
first part of the cold reset cycle is completed, as described above, the 
microprocessor controller 120 sends a signal to a position sensor located 
adjacent to cutter mechanism 604 to determine whether cutter mechanism 604 
is in the up position. If the sensor does not signal back to the 
microprocessor controller 120 that the cutter mechanism 604 is up, the 
microprocessor controller 120 will continue signaling the sensor until a 
specified period has elapsed, at which time the microprocessor controller 
120 will transmit an error message to the control console 800, indicating 
that the cutter is not up. If the sensor is at fault, the operator may 
replace it. The sensor is important, because the cutter must be up when 
the anvils 104, 106 are moved, or damage to the anvils 104, 106 and cutter 
mechanism 604 may occur. 
Once the microprocessor controller 120 logic circuitry has confirmed that 
the cutter mechanism 604 is in the up position, the left arm actuating 
piston is energized to actuate left arm 160 into location adjacent to the 
center of the fixture by solenoid 155, which receives a signal from 
microprocessor controller 120 which causes solenoid 155 to evacuate 
pressure from one side of left arm piston and directs pressure to the 
opposite side to pull left arm assembly 158 into position. 
The microprocessor controller 120 logic circuitry then signals right arm 
solenoid 149 to supply air to right arm piston to actuate right arm 158 
into location adjacent the center of the fixture. Solenoid 149 receives a 
signal from microprocessor controller 120 which causes solenoid 149 to 
evacuate pressure from one side of right arm piston and directs pressure 
to the opposite side to pull right arm assembly 158 into position. 
Microprocessor controller 120 next signals the anvil shift solenoid 159, 
which controls the actuation of double sided cylinder 161 controlling 
anvil. Double sided anvil cylinder 161 is a double acting piston cylinder, 
such that air pressure on the first side of the piston will actuate anvil 
104 left, and air pressure on the second side of the piston will move 
anvil 104 to the right. During the cold start procedure, the signal 
received from the microprocessor controller 120 actuates solenoid 159 to 
cause anvil 104 to move left. 
Microprocessor controller 120 next signals solenoids 163, 165 to supply air 
to front and rear tension centering cylinder piston housings 619c, d. At 
the same time, the lock piston solenoid controlling the lock pistons 630 
on the front and rear ribbon clamp and tension assemblies 153c, d receives 
a signal from microprocessor controller 120 causing it to exhaust air 
pressure from air port 635 on piston 630 thereby exhausting air from lock 
piston 630 causing bumper 641 to actuate away from slide 301 into bore 656 
allowing slide 301 to freely actuate. Microprocessor controller 120 the 
signals tensioning solenoids 145, 147 controlling front and rear 
tensioning pistons 626a, b to actuate the pistons to the tension position. 
After a preprogrammed thirty millisecond delay, microprocessor controller 
120 signals tensioning solenoids 145, 147 to exhaust air from the tension 
side of the tensioning pistons 626c, d and pressurize their opposite 
sides. The left arm solenoid 153 next receives a signal, causing solenoid 
153 to properly pressurize left arm piston to actuate left arm assembly 
160 into the forward position adjacent the front of the cabinet 105. If 
the arm is not sensed as being forward, the microprocessor controller 120 
will again signal left arm solenoid 153 to move left arm 160 forward. 
Again, if the sensor does not send the proper signal to the microprocessor 
controller 120, an error message will appear and the cycle will stop. 
However, if no error or fault occurs, the apparatus is ready for welding 
of ribbon ends. 
The Manufacturing Sequence 
Referring now to FIGS. 1 through 17, the operating sequence for 
manufacturing welded ribbon is disclosed. To begin the operation, the 
operator places a ribbon end through the open door across adjustment 
channels 190b and 190d, and a second ribbon across adjustment channels 
190a and 190c between guide bars 210a, b in each channel 190a-d. After the 
first ribbon end is placed across channels 190b and 190d, the operator 
depresses clamp switch 302b, which signals the microprocessor to actuate 
the solenoid controlling tension clamp cylinder 304 to actuate clamp 300d 
downward to grip the ribbon. The operator then depresses the clamp switch 
302b a second time, and solenoid 143 controlling the cylinder controlling 
clamp 300b actuates clamp 300b downward to grip the ribbon. Likewise, 
after placing the second ribbon end across channels 190a, c, the operator 
depresses front clamp switch 302a, causing clamp 300c on slide 301 to grip 
the ribbon. The operator then presses clamp switch 302a a second time, and 
clamp 300 a actuates downward to grip the ribbon. If any of the steps are 
performed incorrectly, or if the ribbon is misaligned, then the operator 
depresses the reset button 314 on switch plate 180 adjacent to the left 
side of guide plate 186, which signals the microprocessor controller 120 
to open each clamp 300a-d and to open the right arm finger 354 so that the 
operator may reinitiate the ribbon laying sequence. The pressing of 
switches 302a, b and the pressing of reset button 314 operates switches by 
sending a digital signal to microprocessor controller 120 which then 
actuates the appropriate solenoids to actuate the appropriate pistons to 
actuate the clamp and arm components. 
Once the ribbon is in place, the operator presses the palm buttons 171a, b 
and the door closes and the microprocessor controller 120 begins automatic 
operation. The controller 120 signals the appropriate solenoids to actuate 
the tensioning pistons 626 on each tensioning assembly 153c and 153d, and 
likewise actuates piston 619 to retract centering finger 610. This 
sequence of operation permits the tensioning pistons 626 to pull slides 
301 to tension the ribbon. The microprocessor controller 120 is 
programmable to control the solenoid supplying the tensioning piston 626 
to receive air at between 3 and 15 p.s.i. The microprocessor also 
receives, by operator input, the code number for the material being 
welded. The microprocessor controller 120 includes, in memory, 
preprogrammed instructions which supply the basis for selection of the 
proper tensioning pressure. This information is developed by welding and 
then testing welds on ribbon, and determining the optimum pressure to 
obtain the optimum weld strength. 
After a one hundred millisecond delay, the lock piston 630 is actuated to 
press bumper 641 against slide 301 which secures slide 301 against 
movement. The horn 180 is then lowered, and the microprocessor signals the 
horn to control the weld time, hold time and afterburst time. Horn 180 
includes transport assembly to guide horn 180 into engagement with the 
ribbon, a power supply which energizes the horn to ultrasonically weld the 
ribbon and horn stack assembly including the horn energizing components. 
When horn 180 is lowered adjacent the ribbon, a switch is triggered, which 
sends a signal to the microprocessor to begin timing the horn operation 
sequence. The microprocessor is programmable to vary the pre-weld delay 
time and afterburst duration from ten to one hundred milliseconds, and the 
weld and hold time from ten to five hundred milliseconds, or longer if 
required. The microprocessor controller 120 memory contains the proper 
parameters of delay, hold, weld and afterburst time, which are loaded 
therein after acquisition through trial and error testing for each fabric 
ink combination. 
After the weld cycle is complete, the microprocessor controller 120 signals 
the horn solenoid to actuate the horn up. Once horn 180 is in the up 
position, the solenoid controlling the cutter cylinder is signalled, and 
the cutter 604 comes down to trim the ribbon. The right arm finger 354 
then closes on the ribbon before the cutter arm comes down. The 
microprocessor controller 120 signals a sensor to be certain that the 
cutter 604 is down. If the cutter 604 is not down, or the sensor is not 
operating, the controller recycles the cutter solenoid to ensure that the 
cutter 604 is down. If the cutter 604 still does not actuate the sensor, 
the microprocessor stops the operation and an appropriate error message is 
transmitted to the console for display. 
If the cutter 604 is detected down in the cutting position, the 
microprocessor 120 then signals cutter solenoid to actuate the cutter 604 
up. The solenoids controlling tensioning clamp 300c, and clamps 300a and 
300b are signaled, actuating the appropriate pistons to open the clamps 
300a, b and c. Right arm solenoid 149 is then signalled, and right arm 
cylinder is properly actuated to swing the scrap cut by cutter 604 to the 
right side of plate 180. A vacuum, or transvector, is then signalled to 
the on position, and the solenoid 151 controlling finger 354 is signalled 
to drop the waste into the vacuum for disposal. Left arm solenoid 153 is 
then signaled, causing the left arm piston to flip left arm 160 which 
exposes the weld nib to the ironing anvil 106 which simultaneously was 
moved into the place of anvil 104. Solenoid 151 received a signal to shift 
anvil cylinder 161 to the right, disposing ironing anvil 106 under horn 
180. At this point the microprocessor controller 120 again performs a 
status check, determining with a sensor adjacent the left arm 160 to be 
certain left arm 160 is moved to expose the nub. If the arm 160 has not 
moved, or the sensor is inoperative, the microprocessor signals the arm 
solenoid 155 again, to cause left arm 160 to move. If the movement still 
does not occur, or the sensor has failed, the microprocessor shuts the 
sequence down and an error message is sent to console 800 for display. 
Actuation of left arm 160 places the left ribbon end under the area of 
clamp 300b. The microprocessor 120 next signals the solenoid controlling 
clamp 300b to actuate and grip the ribbon end therebeneath. The tension 
position look 630 is then signalled to retract bumper 641, and the tension 
slide 301 will actuate to put tension on the welded ribbon. After a 
preprogrammed one hundred millisecond delay, the piston 630 is again 
signalled to engage bumper 641 against slide 301, locking slide 301 in 
position. The horn 180 is then actuated downward to engage the ribbon and 
flatten the nib. The microprocessor 120 signals the horn 180 to control 
the weld time, hold time and afterburst time. The microprocessor is 
programmable to vary the time pre-weld delay time and afterburst duration 
from ten to one hundred milliseconds, and the weld and hold time from ten 
to five hundred milliseconds, or longer periods of time if required. The 
microprocessor controller 120 memory contains the proper parameters of 
delay, hold, weld and afterburst time, which are loaded therein after 
acquisition through trial and error testing for each fabric ink 
combination. 
After the ironing operation, the horn 180 is moved upward in response to a 
control signal, and the microprocessor signals the appropriate solenoid to 
open the door. The solenoids controlling left and right arms 158, 160 are 
then signalled to actuate left and right arms 158, 160 into their original 
position, and the anvil solenoid 159 is signalled to move the anvil left 
to place welding anvil 104 under horn 180. The vacuum is signalled off, 
left arm finger 658 is opened, clamp 300d is released and the winder is 
turned on. The winder is a separate component which rewinds the just 
welded tape into its cartridge. The winder may be an air powered winder, 
the air supply for which may be controlled by controller 120, or an 
electric powered winder. Tension centering pistons are then turned off, 
and the tension position lock piston is deenergized, retracting bumper 
641. The tension cylinder solenoids 145, 147 then receive an on signal to 
actuate the tension pistons 626 to the on position. After a fifty 
millisecond delay, the tension position solenoids 145, 147 receive a 
signal to turn the tensioning off by reversing tensioning pistons 626. At 
this point a new weld cycle may begin. 
The use of the microprocessor controller 120 to control the operating 
sequence allows simple control and operation of the welder. Further, the 
microprocessor allows independent control of the welding and ironing 
operations, which results in a stronger, more reproducible, weld. 
Selective tensioning of the ribbon to discrete tension levels permits the 
operator to select the optimum tension for any given ribbon fabric type 
and/or fabric ink combination. Unlike the prior art welders where the 
tension was not easily adjustable, the present invention permits the 
selection of ribbon tension independent of operator bias or perception, 
resulting in readily reproducible welds leading to repeatable results. 
Further, as the tensioning piston 326 is actuated by a specified pressure 
for each specific welding operation, if the operator overtensions the 
ribbon when loading the ribbon into the clamps 300a-d, the piston 326 will 
compensate for the over tension. The piston 326, when applied where the 
ribbon is overtensioned, will actuate toward the welder horn 180 because 
the pressure actuating right circular piston 682 away from horn 180 will 
create insufficient force on slide 301 to sustain the preloaded tension in 
the ribbon and the ribbon will relax back to the preselected tension.