Telsonic PowerWheel® welds and crimps aluminium cable securely in tubular cable lug
Aluminium cables are used more and more in automotive on-board power supply systems
(Erlangen) An aluminium cable with a large
cross-section is to be securely welded and crimped at the same time in a
thick-walled tubular cable lug made of copper. What could not be solved by
means of conventional processes can now be realised reliably with the PowerWheel®
technology of Telsonic AG. With a high application of energy within a short
time, the revolutionary ultrasonic welding process connects the aluminium cable
with the copper contact. Furthermore, the tubular cable lug can be sealed
securely by means of heat shrinkable tubing so that it is ensured that the
material does not tear. This means that the ultrasonic welding or crimping
technology established for copper-to-copper joints is now also available for
aluminium-to-copper joints.
"Since we apply large amounts of energy
to the joint zone in a highly concentrated manner within the shortest time
using the PowerWheel® technology, we achieve a welded joint between the
different materials that is closed by adhesive force," explains Axel
Schneider, Sales Manager of the Swiss company TELSONIC AG. The procedure with
the revolutionary PowerWheel® process with its unusual movement pattern results
in a joint closed by adhesive force where only a positive fit is achieved using
other processes. An on-board power supply system manufacturer can thus produce
other connection cables in weight-saving aluminium without having to compromise
on secure contacts.
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