Sonobond equipment not only produces superior metal welds, it also generates important savings in comparison to such methods as resistance welding and soldering. This makes it a win-win for manufacturers because they are able to generate fast, reliable welds while, at the same time, realize substantial energy and other production cost-saving advantages.
Energy consumption is significantly less with Sonobond equipment than with resistance welders. Manufacturers with multiple installations of resistance welders may require a new electrical substation to handle their requirements. On the other hand, ultrasonic welding equipment can usually be accommodated with standard industry power capacity. These cost savings can be illustrated with the assembly of wire harnesses for automotive and similar applications. When resistance welding is used, it requires 20 times more energy than ultrasonic welding. Yet it takes about the same time to make an ultrasonic weld as it does to produce a resistance weld.
High-powered resistance welders, unlike ultrasonic metal welders, require water cooling. This water must often be purified before it can be permitted to enter the waste stream, adding time and costs to the production cycle. Parts may also have to be cleaned before they can be processed by resistance welding equipment. In contrast, Sonobond equipment is fast and environmentally-friendly. It does not require any of these extra steps.
Superior to Crimp & Solder
Wire harness manufacturers report that ultrasonic welding reduces the expense of attaching copper wires by 50% or more over old crimp and solder methods. Ultrasonically welded joints are also stronger, have better electrical conductivity, and weigh less without the mechanical crimp. In short, ultrasonic metal welding produces wire harness joints that are significantly superior to those created by crimping and soldering. Because of this, manufacturers report that the need for costly warranty re-working of wire-to-wire and wire-to-terminal assemblies has been substantially reduced.
Other Money-Saving Advantages
There are even more ways in which Sonobond Ultrasonics’ metal welders offer customers significant savings. Our units require minimal operator training. In fact, the time and effort involved in getting operators up to speed is about the same for our equipment as for resistance welding units and less than that required for crimp and solder methods.
Our microprocessor-controlled ultrasonic metal welders can set and recall up to 250 weld protocols from memory. Welding can be controlled by height, energy or time, reducing the possibility that the operator will make costly mistakes.
There are also built-in features that can represent meaningful savings to customers. For example, all Sonobond metal spot welders use our unique Wedge-Reed design with heat-treated, tool steel Taper Lock Tips. These are manufactured to last for up to 100,000 welds. When the tips finally do need to be replaced, our units are constructed so that this can be accomplished quickly and easily with a minimum of labor and downtime. Some ultrasonic metal welders produced by other companies require replacement of the entire horn, not just the tip. But this is not the case with Sonobond equipment. So we have yet another example of how we help our customers save valuable time and money. Sonobond’s system is also the only ultrasonic system with the capability of welding most oxidized and lightly tinned wires and terminals.
Sonobond’s Ultrasonic Metal Spot Welders
Sonobond leadership in the field of ultrasonic metal spot welding is demonstrated by these units:
- SpliceRite™ Wire Splicer for the lowest resistance, most reliable electrical connections. This machine creates solid-state metallurgical welds of stranded copper wire bundles of up to 60 sq. mm. in size. Tinned wires up to 35 sq. mm. can be accommodated with our 3500-watt power supply.
- Dual Head SpliceRite™ features two ultrasonic welding heads, one on each side of the welding area, for increased welding capacity. The unit confidently handles wire bundles with cross-sectional areas from 48 to 100 sq. mm., including up to 60 sq. mm. wires that are tinned.
- SonoWeld® 1600 Spot Welder performs spot welds, as well as wire-to-terminal welding of non-ferrous metals, including dissimilar metals such as copper to aluminum. The SonoWeld® 1600 is ideal for welding multiple layers and/or delicate foils to tabs or terminals for lithium-ion and NiMH battery assembly.
- Dual Head Spot Welder features two ultrasonic welding heads, one on either side of the welding area, for increased welding capacity. It welds non-ferrous sheet metal, including aluminum up to 3mm thick, and reduces tip sticking on thinner aluminum as used for automotive applications. This unit is ideal for welding up to 80 layers of foil to tabs and terminals, as used for advanced battery and super capacitor applications.
- Ultrasonic Single Point Ground Welder—SPG 2600 is a microprocessor-controlled metal spot welding system for producing the single point ground terminals used in complex automotive electronic components and circuitry. The SPG can weld up to 18 wires to a single terminal with just one pulse before automatically folding the terminal arms to provide stress release on the joint.
Over a Half-Century of Innovation
For over 60 years, Sonobond has been a worldwide leader in the application of ultrasonic welding technology. The company—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding. This was in 1960. Over the intervening years, Sonobond has earned a well-deserved reputation for its pioneering work and quality-engineered products. Today Sonobond manufactures a complete line of ultrasonic welding and bonding equipment. Among the company’s many customers are leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, and apparel industries.
Selecting the Appropriate Sonobond Unit
As part of its dedication to providing top-quality service, Sonobond offers a free, no-obligation Ultrasonic Welding Viability Test. This helps assure that each customer selects the right equipment for their specific application. Once a company decides to incorporate a Sonobond unit into its manufacturing process, every effort is made to make sure the process is as seamless as possible. We understand that every installation is unique. So our personnel work very closely with customers to make sure everything goes smoothly. Anyone choosing Sonobond equipment can count on us for reliable, in-depth technical support before, during, and after installation.”