Energy and Production Cost Savings with Sonobond Ultrasonic Metal Welders Sonobond Ultrasonics
For example, manufacturers with multiple resistance welders may require a new electrical substation to handle the increased energy needs. However, ultrasonic welders can usually be accommodated with standard power capacity.
Resistance welding requires 20 times more energy than ultrasonic welding to assemble wire harnesses. Yet each takes about the same amount of time to make the weld.
High-powered resistance welders require water cooling. The water must often be purified before it can enter the waste cycle. Parts may also have to be cleaned before they can be processed. Sonobond equipment does not require any of these costly extra steps.
Ultrasonic welding of wire harnesses 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. Because of this, manufacturers report that the need for costly warranty re-working has been substantially reduced.
There are also built-in features that provide additional savings to customers. For example, all Sonobond metal spot welders use heat-treated, tool steel Taper Lock Tips. These last up to 100,000 welds. Replacing tips is accomplished quickly and easily. Some other ultrasonic metal welders require replacement of the entire horn, not just the tip. And Sonobond’s patented Wedge-Reed system is also the only one with the capability of welding most oxidized and tinned metals without pre-cleaning.
For over 50 years, Sonobond has been a worldwide leader in ultrasonic welding technology. In 1960, the company—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding. Its most popular metal welders include the SpliceRite™ and Dual Head SpliceRite™ Wire Splicers, SonoWeld® 1600 and Dual Head Spot Welders, and the Single Point Ground Welder—SPG 2600.
Sonobond offers a free, no-obligation Ultrasonic Welding Viability Test to determine which machine best matches the customer's specific application.
For more information, email Melissa Alleman at MAlleman@SonobondUltrasonics.com.
25 July 2011
