Charged EVs | A twist in ultrasonic metal welding

Sponsored by Telsonic.

Ultrasonic-based processes and EVs have a lot in widespread: effectivity, efficiency functionality, reliability, connectivity, and eco-friendliness are among the many important traits that they each possess.

The torsional ultrasonic welding process known as SONIQTWIST® was developed by Telsonic AG in 2006 and shortly established itself because the becoming a member of process for an incredible number of plastics and metals. Torsional vitality is gently exerted on the realm of the joint, thus appropriate even for extremely delicate components. Alternatively, even very sturdy forces could also be utilized in a really brief time, which is crucial, for instance, for becoming a member of aluminum or copper foils. Even painted plastic components might be joined firmly and safely with out leaving seen indentations. The Telsonic progressive torsional welding method has created breakthrough purposes that have been not possible or unacceptable as much as the final decade. Now, the expertise is more and more specified by carmakers to be used in EVs for weight management, battery packaging, cable to terminal connections, bus bars, battery manufacturing and energy electronics. 

Telsonic Torsional SONIQTWIST offers the utmost motion (amplitude) within the periphery. Torsional expertise permits welding of larger-sized welds, extra geometrical shapes, out-of-reach becoming a member of areas, and the place light vibration is required. This has expanded the ultrasonic software spectrum considerably. Many becoming a member of purposes that have been not possible by standard longitudinal welding are actually doable. The truth is, torsional welding is typically discovered to be the one answer for electrical automotive battery producers and within the termination of high-voltage cables. Different examples the place torsional ultrasonic welding proves to be the superior methodology are bus bars, 3D terminals and built-in gate bipolar transistors (IGBT). In plastic welding, the torsional course of permits becoming a member of plastic components with nice contours and openings, corresponding to nozzles, valves or connectors, with out damaging the components themselves in addition to attaching plastic brackets to the within of painted bumpers for holding distance sensors. For the reason that closing motion of the welding system solely takes place within the Z axis, the system could be very simply accessible and permits brief cycle occasions.

Advantages of SONIQTWIST® Welding

  • Very low vibration stress within the decrease half. Only one/10 of stress-induced in contrast with standard ultrasonic weld procedures (excellent for delicate components, electronics)
  • Very brief welding time (typically < 1 second)
  • Good accessibility as just one vertical motion is required
  • Very excessive weld energy might be achieved
  • Complete management choices of the method
  • Far zone welds in centimeter vary
  • No membrane results in foils, tissues and skinny components (no vitality focus within the heart of foil and no gap impact)
  • Nice welding depth doable
  • Rectangular shapes may also be welded securely. Elements would not have to be spherical in form.
  • An influence of as much as 14,400 Watts is feasible
  • Overseas our bodies within the welding seam don’t impair course of

SONIQTWIST welding expertise software overview for metallic elements

  1. Ultrasonic welding pole – The applying requires the welding to happen on the backside of the cylindrical cell by way of the jelly roll, so the ultrasonic welding software has to have an extended attain.
  2. Connection bolt on present conductor – This can be a 360°weld across the bolt that requires a recess on the ultrasonic software. Connecting the bolt on the connector conductor allowed important manufacturing value discount.
  3. Cu washers welded to Al busbars – stopping corrosion.
  4. Battery cap welding – The house is proscribed because the film-style electrical conductor have to be welded into an embossed channel within the battery cap.
  5. Stud welding on connectors or busbar is feasible.
  6. Electrical connection on IGBT – The Cu-plated ceramic printed meeting board in IGBT modules for welding the conductor. The light vibration permits extra constant welds with out damaging the ceramics. The method can also be very forgiving on the nice wire bonds on the DBC. 

As product designers and course of engineers proceed to familiarize themselves with the torsional welding course of and its capabilities, the expertise is positioned to assist propel the EV business to even better heights. We will definitely study extra in time and progressive concepts can be launched, however ultrasonic welding will little doubt be part of the options to attain the aims in materials value, weight and house discount, and fewer labor-intensive manufacturing processes. For extra info, please examine Telsonic’s web site at

About Telsonic:

The Swiss Telsonic Group has been providing its industrial ultrasonic options by way of illustration in Europe, America and Asia since 1966. Fixed improvements assist to make sure that, in lots of purposes, Telsonic has established a lead over opponents that provides added worth to prospects. With over 250 extremely certified workers, the owner-managed firm makes a speciality of plastic and metal welding in addition to ultrasonic cleaning and sieving. All around the world, prospects in fields corresponding to automotive, packaging, and medical expertise worth the corporate’s complete providers and broad vary of ultrasonic elements for system building in addition to its full welding techniques.

Sponsored by Telsonic.

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