Applications and Uses for Ultraweld® Magnet Wire Termination: Brief #7
The application described here is an example of how the many benefits of ultrasonic welding have been applied to improve productivity and quality.
END USE: Joining windings in coils, chokes, transformers and motor windings and/or connecting flexible transition leads to these components.
MATERIALS: Enamel insulated copper magnet wire and untinned or silver or nickel plated stranded wire.
EQUIPMENT: AmTech Ultrasonic welder suitably tooled for the specific application.
PROCEDURE: Wires to be joined are placed into the welding tool. The weld cycle is initiated, enamel insulation as well as surface oxides and contaminants are disbursed and a high quality electrical connection is made in one operation.
ADVANTAGES: The electrical and thermal properties of an ultrasonic weld are unrivaled by any other process. Ultrasonic welding is a mechanical process. No electrical current passes through the work piece 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).Compared to non-welded connections, expensive crimps are eliminated. Finally, the welding variables can be precisely monitored and controlled providing consistent results and SPC capabilities.
ADVANTAGES: The electrical and thermal properties of an ultrasonic weld are unrivaled by any other process. Ultrasonic welding is a mechanical process. No electrical current passes through the work piece 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).Compared to non-welded connections, expensive crimps are eliminated. Finally, the welding variables can be precisely monitored and controlled providing consistent results and SPC capabilities.
