EQUIPMENT: AmTech Ultrasonic welding system consisting of multiple welding heads for making simultaneous welds on a totally automated production line.
PROCEDURE: Wires and switch assemblies are loaded into pallets The pallets are indexed into a triple headed welding stations. Five wires are terminated to two switch assemblies in one cycle of the welding station.
ADVANTAGES: The low temperature characteristic of the ultrasonic weld leaves the vital spring properties of the beryllium copper wiper unaffected. Ultrasonic welding is a mechanical process. No electrical current passes through the workpiece and no melting occurs. The process, therefore, is ideal for welding highly conductive alloys since the resistivity of the materials to be joined is not a factor. Compared to fusion methods for joining metals, ultrasonic metal welding provides the lowest cost per weld. This is achieved through lower power consumption (1/30th that of a comparable resistance welder), superior tool life and lower labor cost (because ultrasonic welders can be operated by unskilled labor.) Finally, the welding variables are precisely monitored and controlled providing consistent results and SPC capabilities.
ADVANTAGES: The low temperature characteristic of the ultrasonic weld leaves the vital spring properties of the beryllium copper wiper unaffected. Ultrasonic welding is a mechanical process. No electrical current passes through the workpiece and no melting occurs. The process, therefore, is ideal for welding highly conductive alloys since the resistivity of the materials to be joined is not a factor. Compared to fusion methods for joining metals, ultrasonic metal welding provides the lowest cost per weld. This is achieved through lower power consumption (1/30th that of a comparable resistance welder), superior tool life and lower labor cost (because ultrasonic welders can be operated by unskilled labor.) Finally, the welding variables are precisely monitored and controlled providing consistent results and SPC capabilities.
