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Weld Heavy Wires to High Voltage Terminals Used in Electric and Hybrid Vehicles Without Causing Fracturing

Produce Higher-Strength Welds Using Lower Power with Our Ultrasonic Dual Head Welder

Automotive component manufacturers now have a reliable, environmentally friendly and cost-effective solution for assembling high voltage terminals used for storage in electric and hybrid vehicles. Sonobond Ultrasonics’ Dual Head Spot Welder, equipped with special tooling, can weld heavy wires up to 80 sq. mm. cross sectional area without fracturing the terminal. Additionally, it achieves a higher- strength weld using lower power than other ultrasonic welders, and a more durable weld than crimp or solder methods.

Designing an Assembly Solution

As an example, a leading international automotive component manufacturer was getting a high percentage of cracked terminals when using a competitor’s 5000-watt ultrasonic welder for assembly. The damaged terminals had to be scrapped. By using our 3500-watt Ultrasonic Dual Head Spot Welder, equipped with custom tooling we designed for their specific application, Sonobond enabled the company to make high strength and durable welds with no cracked terminals. To meet the company’s needs, we considered the geometry and specifications of the finished product, and then created tooling to hold the wires in the proper orientation while welding, but without unnecessarily complicating the load and unload operations.

Distinctive Features of the Dual Head Spot Welder

The Dual Head Spot Welder has the unique ability to weld lightly tinned and oxidized non-ferrous metals by employing Sonobond’s patented Wedge-Reed System that combines high vibratory force and low- amplitude coupling.

Metal Welding Viability Test Without Obligation

You’re invited to utilize our Free Ultrasonic Welding Viability Test. We’ll use your own materials and produce sample welds so you can see the results of ultrasonic welding for your specific application and requirements before you buy.

Typical Assembly Applications:

  • Spot welding,
  • Wire-to-terminal welding,
  • Wire-to-wire welding,
  • Electrical wire harnesses,
  • Bus bars,
  • Lithium-ion battery terminals,
  • Foil-wound capacitors,
  • Thin aluminum or copper foil,
  • Electrical contacts,
  • Fuses/circuit breakers,
  • Ignition modules,
  • Starter motors,
  • PV panel interconnects,
  • HVAC tubing.

To learn more about how we can expedite the repair and upkeep of your commercial or industrial equipment, or to get a free estimate on any of our services, call Rochester Industrial Services Inc today at 888-349-4638, or write to us through our website’s contact page.

SORRY FOLKS—WE DON'T REPAIR CONSUMER PRODUCTS. Rochester Industrial Services, Inc. is an industrial repair facility. We repair, refurbish, maintain, and service all types of industrial and commercial equipment. Unfortunately, we are NOT set up for repair of household items

NOTICE: Rochester Industrial Services, Inc. is an independent repair facility and is neither affiliated with nor endorsed by any particular equipment manufacturer listed on our website. Any and all trademarks, trademark names, and service marks remain the property of their respective original equipment manufacturers. We do not influence nor are we in any way involved with the original equipment manufacturers. We do not control any facet of the manufacturing, distribution, or repair processes engaged by the OEM for any equipment listed on our website. Unless specifically noted, we do not offer factory authorized warranty service for any item.