Welding by distance is a method of controlling the ultrasonic welding process based on the distance traveled by the ultrasonic horn during the welding cycle. In this method, the ultrasonic generator is programmed to deliver a specific amount of energy to the joint, based on the distance that the horn has traveled during the welding cycle.

To achieve a consistent, high-quality weld using welding by distance, it is necessary to carefully control the position and movement of the ultrasonic horn, as well as the applied pressure and other process variables. By measuring the distance traveled by the horn during each welding cycle, it is possible to monitor and control the welding process in real time, and adjust the process parameters as needed to achieve optimal results.

Welding by distance is a relatively new method of ultrasonic welding control, and is not yet widely used in industrial applications. However, it offers a high degree of precision and consistency, and has the potential to optimize the welding process for a wide range of materials and part geometries. As with other methods of ultrasonic welding control, it is important to carefully control all process variables to achieve optimal results.