Applications Automotive

The Torsional PowerWheel® system was utilized to clear the connector height and achieve a superior quality weld for both 35 mm^² and 50 mm² cables with the SQ4 terminal.

35 mm² high quality cable is used to terminate this Rosenberger connector with limited space for the 35 mm² cable.

Battery cells in an electric vehicle are connected using aluminum stampings. These connecting elements should also be detachably connected to a copper busbar.

Eyelet terminals are used for attaching grounding connections to the motor vehicle chassis. The individual cores must be firmly welded within the lateral terminal limits. 

95 mm^² cable with 3,000 flexible fine strands of 0.2 mm diameter is used to terminate the Staubli terminal with limited space for required weld width of 22 mm.

Prefabricated stand-up and sealed-rim bags must be sealed tightly with a top seam after filling. 

Packaging lettuce from 30 µm-thin tubular bag films up to 320 mm wide places high demands on the sealing unit. BOPP films are often used for food products. 

For the production of conductive coatings in battery business

Reliable sieving of weld spatters only with ultrasound in the standalone system

Joining different material components by means of ultrasonic riveting. Simultaneous forming of two rivet heads.

Reliable joining of metal with plastic through ultrasonic riveting with differential parts scanning.

Low-vibration and secure joining of electronic components through ultrasonic riveting.

Tight welding of injection-moulded parts without additional sealing elements with continuous process monitoring.

Securing the metal drive plate in an adjustable and low-particle manner onto a plastic disc data carrier.

Ultrasonic embedding of the metal SonicLok threaded bolt inserts into a plastic housing in a durable and low-tension manner.

Simultaneous ultrasonic embedding of four threaded bushes into a POM cover flange so they cannot be extracted.

Ultrasonic joining of a two-part injection-moulded dosing cap with a curved surface in a liquid-tight manner without markings.

Reliable welding of the two-part outlet chamber in a liquid-tight manner. Joining other applications on the same installation without long retooling times.

Liquid-tight joining of injection-moulded halves of an adapter, without loose particles if possible. The visible joining seam must not be visible through the transparent plastic.

Tight torsional ultrasonic sealing of a thin-walled, delicate blow-moulded part from the medical sector with a film without damage.

Securely sealing the openings on components for medical technology with a membrane made of non-woven material without damage. The torsional SONIQTWIST® technology offers interesting advantages.

Tightly welding the two-part damper housing made of semi-crystalline POM. The joining zone is formed as a pinched-off seam. TCS5 process controller with convenient touch screen.

Removing the filter rounds with ultrasonics and simultaneously sealing the edge zone without fraying. The housing is hermetically and permanently welded after inserting the rounds.

High torsional strengths and stabilities can be achieved because of the ultrasonic embedding of metal thread inserts. All inserts are embedded in one process step.

Torsionally removing the filter net round from the base material in one process step with ultrasonics and welding to the cap without damage. Integrating the process into an automatic production installation.

Securing insulation to a plastic cover at several points using ultrasonics. The process is carried out in a special plant with integrated IPA3505 actuator units.

Despite the absence of a specific connection seam, an ideal connection is achieved by means of ultrasonic spot welding of two flat components.

Protecting the opening in an electronic component against the ingress of dust with a fleece filter. Economical manufacturing of square filters with sealed edge zone and pointed corners with ultrasonics.

Cutting out antiseptic dressings with additional functions from the base material with ultrasonics and sealing the edge zone against fraying at the same time.

Softly sealing the edge zone of breathing masks with ultrasonics for high wear comfort. Additional insertion of high-strength strap openings.

The production of face masks requires various separation and joining tasks which can be carried out perfectly with ultrasonics.

Covering soft plastic foam rings for headphones with synthetic leather. All the required work processes should be carried out as far as possible in one setting.

Compresses with various edge zones. Complete manufacturing of the compresses with ultrasonics in one process step. Removing the shapes and welding the edge zone at the same time.

Securing electrical conductor tracks with zero backlash at several positions through ultrasonic riveting and individual path limitation.

Securing the silicone ball in the plastic part in a reliable, particle-free and tight manner. Fully automatic manufacturing with process and quality monitoring.

Torsional welding of membranes for temperature, pressure and humidity compensation onto a ventilation opening in an aesthetic and tight manner with minimal particle flight.

Joining injection-moulded plastic parts with a three-dimensional surface with stud welding.

Torsional ultrasonic welding of PTFE membranes into the ventilation opening of a housing in a tight, particle-free manner without damage.

Ultrasonic far-field welding of the cylindrical, stepped plastic inlet with amorphous structure to the swirl chamber without sealing elements.

Tight welding of a memory chip into a two-part polyamide housing with high amplitude requirement. Using a sonotrode made of high-strength titanium alloy.

Ultrasonic welding of sensor supports into painted, thin-walled bumpers without spoiling the appearance of the visible side.

Tight welding of a panel with a curved surface onto a plastic housing with LEDs without damage with a carefully designed joining seam.

Accurate ultrasonic welding of the two housing halves of an electronics coupler into the right position. Integrating the ultrasonic joining process into the automatic production line.

Tight welding of a reflector made of PMMA onto a rectangular ABS/PC housing without markings. Monitoring the welding quality and recording the process parameters.

Ultrasonic welding of a nipple with attached springs in a tight manner and without damage to an injection-moulded automotive part made of PA6.6 GF.

Welding a large inspection window into the cover of an electricity meter without any markings and in a precisely parallel position.

Tight torsional ultrasonic sealing of the compensation opening of a housing part with a delicate membrane without resulting in a "membrane effect".

Tightly sealing a pressure equalising port with a filter membrane. Torsional welding of membranes pre-punched with vacuum technology without damage.

Punching the switch foil out of the base material and welding it in a watertight manner into a housing at the same time. Quality assurance by monitoring the parameters and recording the process data.

Welding a sensor with sensitive electronics into the housing. The electronics components are not damaged due to the correct joining seam design and the frequency selection.

Cost-effectively securing the electronics circuit board to the connector assembly with ultrasonics without damage. Spring-loaded rivet unit for small-diameter rivet shafts.

Hermetic welding of an end cap after filling the cartridge. Thanks to ultrasonics, no adhesives or solvents are required for joining.

Tightly welding a membrane into a medical part. The torsional SONIQTWISTÒ technology enables particle-free cutting and joining. The film remains smooth and undamaged.

Tight and particle-free welding of a previously mechanically punched-out membrane into a medical plastic component without damage.

Despite the absence of a specific joining seam, thin, flat and flexible knitted material can be reliably connected by ultrasonic spot welding without any problems.

Precise and economical compacting of the end of electrical cable sets in various configurations. Quality control integrated in the production process.

Economical and reliable manufacturing of strand node connections made of Cu/Cu, Al/Al or Al/Cu with the same quality. Quick conversion of the production installations with the same quality.

Welding the strand end nodes for the board assembly wiring harness. Handling, accessibility, KSK compatibility and quality control are important prerequisites.

Welding an aluminium cable to a two-part terminal after both contact parts made from different metals have been welded and tightly overmoulded with plastic.

Permanently connecting an Al current conductor running through the body with a 120 mm2 Al cable with the lowest possible loss of current conduction.

Welding an Al cable with 60 mm2 cross-section onto a nickel-plated, angled Cu terminal. The weld itself should be as narrow as possible.

An aluminum busbar with a cross-section of 120 mm2, which is designed for high currents, should be provided in an electric vehicle as the connection to the traction battery. 

Contacting an insulated Al current conductor with current taps in any position in a fully automatic and secure manner. Expensive partial insulation before making the contact should be avoided.

Electrical welding with ultrasonics of a mixture of Cu and Al strands in various configurations with as little contact resistance as possible.

Welding an aluminium cable with a cross section of 120 mm² to a nickel-plated copper terminal. The weld should be as narrow as possible for design reasons.

Welding a Cu high-voltage cable with a cross-section of 70 mm2 onto a Cu contact. Maximum welding width 15 mm. Tension and shear loads must reach the specified values.

Welding two fine strands with 2 x 50 mm² cross-section (total 100 mm²) on a silver-plated Cu terminal. Significant reduction of the welding width of 30 mm as a result of the smaller installation space.

Electrically connecting terminals for battery contact with Al cables with a 35–42 mm2 cross-section in a reliable manner. Simple adaptation of the welding system to various cable sizes.

Electrically connecting MAS terminals for high-current applications in vehicle construction with Cu cables in a reliable and conductive manner. Simple adaptation of the welding system to the different product variants.

Reliably compacting the end of a high-flex cable with 35 mm2 cross-section. Welding further cross-sections as well as cable types as end or intermediate nodes.

Securely welding an Al cable with 85 mm² cross-section in a nickel-plated Cu tubular cable lug with a wall thickness of 0.8 mm. Pull-out strength must meet specified value.

Cost and weight savings in vehicle construction. Contacting an insulated Al current conductor with a bolt with SONIQTWIST^® technology.

The objective to fasten a busbar with a screw in a cost-efficient way while still maintaining the electrical conductivity. 

The KERN-LIEBERS Group, a producer of precision stamped parts, has developed a technique for coating aluminum busbars inline with silver.

Ultrasonic welding of polyethylene strips for geocells to form a honeycomb structure.

Torsionally welding a compensation membrane onto an aroma protection valve with SONIQTWIST^®  technology tightly without damage at high production rates.

Removing medical dressings consisting of several layers for wound-healing applications and reliably sealing the edge against fraying in a single process step.

Cutting breathing masks, filters, antiseptic dressings or labels with ultrasonics and welding the edge zone.

Cutting blind textiles to the right width and length with ultrasonics and reliably sealing the edge zone at the same time.

Continuously and intermittently separating woven labels along the width and the length with ultrasonics. Soft and sealed edges with high wear comfort.

Clean, industrial cutting of sandwiches with ultrasonics at high speeds without squashing.

Industrial cutting of cakes without squashing the product and without products sticking to the blade.

Clean cutting of cakes and biscuits without products sticking to the blade. Industrial processing with high utilisation factor.

Sealing the packaging bag reliably and tightly after filling, even if the welding area is contaminated.

Sealing beverage packaging tightly through the liquid and welding in the pouring spout. Detecting leaking packaging by means of process data monitoring.

Reliably and tightly sealing containers and tins with torsional SONIQTWIST® ultrasonics sealing technology.

Attaching a cardboard label header after filling and sealing tubular bags. The high production capacity requires short process times.

Screening carbon powder with a wide grain size range without a throughput bottleneck forming on the upper sieve decks with small mesh sizes.

Screening tungsten powder with small grain size distribution with fine mesh width and high throughput.  Ultrasonic technology increases the throughput and reduces the risk of clogging.

Screening medical powder for tablets with optimal separation precision. Keeping the screen fabric free from clogging for a long period of time for the required grain size tolerance.

Determining the grain size distribution of ground, classified pigment powders using ultrasonics-supported screening analysis.

Visually perfect surfaces thanks to the precise fractionation of the powder and minimisation of the amount of incorrectly sized grains thanks to ultrasonic support in screening machines.

Cutting fabric or other materials with ultrasonics and, if required, simultaneously welding the edge. Producing any shapes in x/y systems and with 3D robots.

Torsional welding of shock absorbers at the base and lid through the oil to produce an oil-tight and gas-tight seal.

Economically removing even cut-outs for respiratory masks and sealing the edge zone for good wear comfort in one process step. 

Electrically contacting a delicate ceramic printed circuit board coated with copper conductor tracks with a long pin with the lowest possible contact resistance.

Welding a large number of battery current collector foils made of Cu to a Ni-coated Cu collector with minimum loss of power.

Standardized terminals are mainly used in vehicle construction for high-current applications. The welding system must adapt to different cable dimensions and terminal sizes.

Eyelet terminals are used for attaching grounding connections to the motor vehicle chassis. The individual cores must be firmly welded within the lateral terminal limits. 

Contacting Cu-coated IGBT ceramic printed circuit boards at various points with optimum electrical conductivity. The SONIQTWIST® technology is used for accessibility reasons.

Owing to the increases in the price for copper, aluminium is becoming more and more important. Ultrasonic welding technology is just as suitable for aluminium strands as it is for copper strands.

Electrically contacting an Al battery cap with a Cu current collector in a recess in the component in a reliable manner.

The Mini HPLB plug contact from Royal Power Solutions should be welded to a short busbar made of silver-plated copper for a 12 V distribution in a vehicle.

A deep-drawn cap to a capacitor needs to be electrically connected to a contact bow. Both components are made of aluminum.

Compacting or welding a twisted Cu strand with a cross-section of 160 mm² to a high degree. Single wires must not be damaged.

Securely and quickly compacting a copper braid at the ends with ultrasonics.

Welding punched Cu contact studs onto a delicate Cu punched strip during the manufacturing process. No damage to the contact tracks and minimal electrical contact resistance.

Welding threaded bolts or supporting rails to a deep-drawn Al housing for electronic components with SONIQTWISTÒ technology.

Flush welding flat, rectangular copper conductors using ultrasonic technology without substantial thickening due to overlaps.

Fractionating soldering powder in various qualities and large quantities with SONOSCREEN®easy in double-decker screening systems with excellent separation precision. 

Screening fine makeup powder in large quantities, different colour shades and different qualities with high throughput rates and without any clogging of the screen.

Aluminium oxide is processed in various industries. The screening system must fulfil strict requirements with regard to capacity, screen life and separation precision.

Sugar is available in different qualities and grain sizes. A high throughput rate, fractionation and dedusting must be provided by means of a suitable process.

Engines comprise many individual high-precision components. The parts must be cleaned in a reproducible manner before a subsequent process step.

Reliably removing residual dirt from pistons and connecting rods for final engine assembly using ultrasonics. Controlled by ProfiNet bus systems

High cleaning standards for surface-treated components such as exhaust systems. Fully automatic, reliable and reproducible cleaning with ultrasonic tube resonators.

Removing oil, dirt, polishing paste or machining residues from small parts after final manufacture. Cavitation of ultrasonic tube resonators even reaches concealed places.

A current-safe connection of a 95 mm² HV copper line on a copper terminal is to be established. The tight installation space requirements are the greatest challenge. 

For an electrical charging socket with very limited interior space, a copper plug contact with a copper cable and a cross section of 95 mm2 with excellent electrical conductivity and minimal contact resistance needs to be connected.

As a result of the trend towards miniaturization, housings with integrated cable connections are to be increasingly space-saving, which is why the stripped cable ends must become increasingly shorter.