Ultrasonic welding machine splices wire bundles with one pulse

Sonobond Ultrasonics offers the Dual Head SpliceRite™ ultrasonic wire splicer. It accommodates large wire bundles with one pulse, handling stranded copper wire bundles with cross sections of 1.89 to 3.94 sq. in. It also handles lightly tinned or oxidized wires up to 2.36 sq. in. without precleaning.

The unit features upper and lower welding heads, and the tip and anvil are activated ultrasonically. It uses the patented wedge-reed bonding system of high vibratory force and low-amplitude coupling. Shear mode vibration, parallel to the welding surface, is used while the line of force is directly over the parts to be welded, producing welds without bending stress or stalling, the company states. Welds are made with high conductivity and low voltage drop, without arcs, sparks, or fumes and without melting the weldment.

Tool steel taper lock tips provide foolproof placement and can last up to 100,000 welds, the company reports. Because the tips are nonacoustic, they need no calibration. The microprocessor controller stores 250 jobs. Welds can be controlled by height, energy, or time.