Applications and Uses for Ultraweld® Terminate Copper Braided Brush Wire and Primary Power Cables: Brief #8
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: Automotive Anti-Lock Brake System.
MATERIALS: Braided copper brush wires, I 10AWG stranded wire power cables and copper terminals.
EQUIPMENT: AmTech Ultrasonic welder equipped with a special indexing fixture.
PROCEDURE: The motor end cap is loaded into the fixture. The braided brush cable is placed into its terminal. The weld cycle is initiated, surface oxides and contaminants are disbursed and the braid is welded to its terminal. The fixture indexes to the next position and the process is repeated. The power cables are welded in a secondary operation.
ADVANTAGES: Ultrasonic metal welding is a mechanical process that is easily automated. 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. Electrical and thermal properties of an ultrasonic weld are unrivaled by any other process. 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-welding techniques, superior electrical conductivity is achieved and expensive crimps are eliminated. Finally, the welding variables are precisely monitored and controlled providing consistent results and SPC capabilities.
ADVANTAGES: Ultrasonic metal welding is a mechanical process that is easily automated. 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. Electrical and thermal properties of an ultrasonic weld are unrivaled by any other process. 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-welding techniques, superior electrical conductivity is achieved and expensive crimps are eliminated. Finally, the welding variables are precisely monitored and controlled providing consistent results and SPC capabilities.
