The World s First Servo Ultrasonic Spot Welder. Dynamic Force and Amplitude Control with Multi-Step Welding

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1 Digital Servo Spot Welder US-935S The World s First Servo Ultrasonic Spot Welder U.S. Patent Pending Dynamic Force and Amplitude Control with Multi-Step Welding Specifications Frequency 35 khz nominal Ultrasonic Power 900 W max Power Supply 220Output 240 VAC single phase; 16 Amp max; Nema 6-20r outlet Weld Force ~440 Newton maximum Weldhead 18.2 kg / 50.8 x 45.7 x 17.8 cm 40 lb / 20 x 18 x 7 inches Controller 33 kg / 40.6 x 50.8 x 22.9 cm Cabinet 71 lb / 16 x 20 x 9 inches Ability to adjust force and amplitude during the weld cycle to optimize parameters for each specific application Capability of over 20 weld steps with unique force and amplitude parameters while energy and frequency remain constant Soft-Touch Landing for Welding Delicate Parts Visual Display 17 inch LCD display and mouse Additional Table / Touchscreen Monitor Options Barcode Scanner Ability to weld small, delicate foils and tabs without tearing or breaking of materials Industry Leading Missing Volume Detection Welding Capabilities Applications Material Type Cu & Al Foil Welding Foil to Tab Non-ferrous Copper (Cu) Aluminum (Al) Single micron resolution with load cell force feedback Measurement of pre-weld and post-weld height Ability to detect single missing foils from a stack Consistent measurement and ultrasonic output produce high cpk values Network Compatible Logs weld height, weld energy, & weld time Saves last 20,000 welds; export via USB or TCP/IP Doc#B10031

2 Versatile Solutions in the Battery, Wire Harness, Automotive Manufacturing, Medical, and Defense Industries TECH-SONIC has been providing industry support on a Multi-National level for over two decades US-935S Ultrasonic Controller Cabinet Multi-Step Welding: this teach screen displays the ability to utilize multi-step welding with variable force and amplitude control. The first-step is a compression stage without ultrasonic energy, followed by the changing of parameters during the next step, and a final compression stage to measure height. TECH-SONIC offers comprehensive multi-national support and service! United States, Headquarters Columbus, Ohio info@techsonicultrasonic.com China (Shenzhen) Nanshan, Shenzhen, Guangdong tsc@techsonic.com.cn Philippines Basak, Lapu-Lapu City dante.d@techsonicultrasonic.com China (Suzhou) Industrial Park, Suzhou tsc@techsonic.com.cn Mexico Germany Thailand India Ciudad Juarez, Chihuahua rosendo@techsonicultrasonic.com Bang Na, Bangkok atthapol.c@techsonicultrasonic.com Website Address 2710 Sawbury Blvd. Columbus, OH USA Phone info@techsonicultrasonic.com Obertshausen, Germany k.bauer@techsonicultrasonic.com Janakpuri, New Delhi sushant@techsonicultrasonic.com Doc#B10031

3 Servo vs. Pneumatic Ultrasonic Spot Welder Comparison Servo US-3020S, US-5020S, US-935S Driven by servo motors Dynamic Force and Amplitude Control Multi-step welding capability Soft touch landing on weld materials controlled by servo Option for a set home position, lower level than fully open position Single missing foil detection Large, graphic weld feedback display using Windows CE on 17 monitor Storage of up to 20,000 weld programs CSV weld data exportable via USB or TCP/IP US-3020C Controller Automatic height calibration Pneumatic Viper-20, US-3020P, US-935P Driven by pneumatic cylinders Constant weld force and amplitude Single step welding Aggressive landing controlled by pneumatic cylinder Must return to fully open position each weld cycle Can not detect single missing foils Small, simplistic weld feedback display on 3.2 screen (only Viper-20) Storage of up to 99 weld programs RS-232 output data Viper-20 Controller Pin gauge height calibration

4 Servo-Controlled Ultrasonic Welding of Tabs and Foils in Lithium Battery Assembly TECH-SONIC is the first manufacturer to develop a highly-advanced servo-controlled ultrasonic metal welder, including spot welders for lithium battery assembly. It combines the latest technologies in ultrasonic welding, servo control, user-friendly microprocessor control, and load cell force feedback, providing a 100% digital welding process. Having been involved in lithium battery welding since 1996, TECH-SONIC has been working with many of the leading battery manufacturers of the world over twenty years of operation. With long established expertise in lithium battery welding, TECH-SONIC has been working with these manufacturers on new advanced solutions in welding foil stacks, foil-to-tab, foil-to-busbar, and tab-to-busbar (see figures 1 & 2) to meet the needs of assembling current and future batteries. Figure 1. Small size lithium battery for portable devices Figure 2. Large size lithium battery for EV TECH-SONIC has gone beyond the latest ultrasonic metal welding technology by adding servomechanism control to ultrasonic welding, thus producing a full digitally controlled welding process that responds to the various dynamics of today s critical welds. Servo ultrasonic spot welders provide accuracy, repeatability, and reliability, especially in the welding of copper or aluminum foils which are a base material as anode and cathode in lithium battery designs. This patent pending line of machines allow for Dynamic Force and Amplitude Control coupled with multi-step welding to create the optimum welding parameters for the often-challenging foil and tab welds. With single-micron resolution linear encoder, servo ultrasonic welders are able to detect weld height changes relative to a set tolerance window with greater precision an accuracy than their pneumatic counterparts. For example, TECH-SONIC s 3.0kW servo spot welder, model US-3020S (figure 3), can detect one single missing or added foil in a stack of sixty (the thickness of a foil is around 8-10um) and signal the error to the user before initiating the welding sequence. Typical pneumatic welders do not have missing or added foil detection capability with such precision. 1

5 By compressing the foils or tabs being welded with soft touch landing of the ultrasonic horn (sonotrode), servo ultrasonic welders can reduce or prevent foils breaks and cracks by reducing stress and allows no coating damage by ultrasonic vibration. Often in pneumatic processes, the top layers of foils are cracked by the violent descent of the horn. Figure 3. US-3020S Servo Ultrasonic Spot Welder Conventional pneumatic ultrasonic metal welding machines also require larger, bulkier parts to support the high force produced by the pneumatic cylinder during welding. Such high force requires increased amounts of power of 5.0kW or more to create necessary friction between parts. Higher power also introduces additional stress and wear on the tooling which increases likelihood of horn cracking damage and decreases tooling life. TECH-SONIC tooling can extend life cycles depending on material thickness and the size of the horn by minimizing power requirements and optimizing the amount of energy and force needed to create solid bonds. The use of optimum force and energy though Dynamic Force and Amplitude Control open opportunities for end-users to weld larger stacks of foils with a wider weld area (due to a wider horn). Welding stacks of foils or tabs to busbar is also possible while maintaining the same power requirement and limiting the amount of rifts surrounding the weld area caused by ultrasonic vibration. For delicate applications, TECH-SONIC also has a 900W servo ultrasonic welder, model US-935S. This machine possesses many of the same features as its 3.0kW companion in a scaled down version to weld with much smaller delicate parts. It is able to detect single missing or added foils and tabs in a stack and has a smaller weld area for precision welding. The lower power and higher frequency make this the ideal solution for batteries used in mobile phones, credit cards, and other small devices. TECH-SONIC servo ultrasonic welders include simple, automatic calibration mechanism for ideal repeatability and accuracy. The machines are based on the reliable Windows CE operating system and can provide TC/IP interface for transfer of production information to a host system via USB, where it can be saved and analyzed

6 TECH-SONIC, Inc. is headquartered in Columbus, Ohio, with subsidiaries in China, and sales and service offices in Mexico, Germany, India, Thailand and the Philippines. It has been designing and manufacturing high-tech ultrasonic metal welders since In recent years, the company has devoted its research and development to servo controlled ultrasonic metal welding the Holy Grail of ultrasonic metal welding. As a pioneer in servo ultrasonic metal welding technology, TECH-SONIC integrates the latest electronics, hardware, location and force sensors, and control software in new and unique ways. TECH-SONIC has been serving global companies in electrical, automotive, EV, battery, wire harness, appliance, HVAC, solar, and military industries throughout the world, and in addition, its engineers have many years of experience in custom welding systems. To demonstrate that TECH-SONIC equipment can meet your welding needs and assembly specifications, the company provides free welding sample testing. For more information and to apply for free sample testing, please visit our website For immediate assistance, call Frank at or info@techsonicultrasonic.com. 3

7 TECH-SONIC US-935S Servo Spot Welder Video Links YouTube US-935S Servo Spot Welder Demo Vzaar (International Safe Link) US-935S Servo Spot Welder Demo (Alt)