Ultrasonic Smart Welding (large)
Smart Welder SW1089
Product Description
The Smart Welder SW1089 is an ultrasonic welding machine with a large, fully accessible working area for terminals, pins, copper rivets, and sleeves. It combines the force and ultrasonic power of welding equipment with the precision, speed, and advanced process control of wire bonding machines.
Smart Welders ensure precise positioning of the sonotrode, with an image recognition system determining the exact weld location quickly and accurately. This allows for small pitching and compact, high-power density products.
Advanced functions include touchdown sensing, precise dynamic contact force control, process monitoring (ultrasonic characteristics and deformation), and standardized interfaces for assembly line integration. Smart Welders can handle a wide variety of products, requiring only program changes and possibly adapted clamping and automation for new products.
Key Features
- Fully automatic ultrasonic welder with a very large working area up to 392 mm x 870 mm
- Welding of terminals, pins, copper rivets and sleeves using different sonotrodes and machine setups
- Image recognition for detection and correction of weld locations
- Active vertical axis
- Rotational p-axis for angle optimized process results
- Wide range of ultrasonic (US) power
- Ultrasonic welding as cell contacting system for battery applications
- Narrow pitch and deep access due to long, narrow sonotrodes and pattern recognition supported positioning
- Zero gap is performed by touchdown process not by clamping
- Touchdown sensor to avoid damage to sensitive contact components
- Precise and dynamic force control
- Programmable welding maps with multi-interval processes
- Individual parameters per weld
- Flexibility to handle a large variety of products
- Standardized interfaces for line integration
- Automotive accepted process control (PiQC, patented)
Technical Specification
Flexibility
- Flexible use of the working area, e.g. vacuum clamping
- Maximization of throughput by automation (two/more parallel lanes)
Quality
- Process integrated Quality Control (PiQC): detection of further parameters,
e.g. friction behavior by additional sensor system for 100 %
quality monitoring in real time (patented); as option - Full traceability of all relevant process data
Working area
- SW1089 – 400W & 1500W: 392 mm x 870 mm x 50mm
Footprint
- SW1089: 930 x 1823 x 2040mm