Patent ID: 8672211

Claim:
A vibration welding system comprising: a process controller that is configured to control the vibration welding system in part using a measured control value; an anvil having a first textured working surface; a welding horn having a textured welding pad with a second textured working surface, wherein the anvil and the welding horn are configured to clamp a work piece between the first and second textured working surfaces during a vibration welding process; and a thin film sensor that includes a plurality of thermopiles in communication with the process controller, wherein: the thin film sensor is positioned immediately adjacent to a designated one of the first and second textured working surfaces; the thin film sensor is configured to measure a temperature value as the measured control value with respect to the designated first or second textured working surface, and to transmit the measured control value to the process controller; and the controller is configured to: determine heat flux values of the first or second textured working surface using the measured control value as a weld is being formed; compare the determined heat flux values to calibrated heat flux values or ranges of heat flux values; and execute a control action with respect to the vibration welding system when the determined heat flux values match the calibrated heat flux values or ranges of heat flux values, including determining whether the first or second textured working surface is substantially worn and requires repair or replacement, and recording a diagnostic code requesting the repair or replacement.