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.