Smart Welder SW1085 – with rotational weldhead

Smart Welder SW1085 – with rotational weldhead

Best of both Technologies: ultrasonic welding & wire bonding

Hesse Mechatronics Smart Welder combine the best of two technologies:

  • The force and ultrasonic power of ultrasonic welding equipment
  • The flexibility, precision, speed and advanced process control features of wire bonding machines.

Smart Welding is the leading-edge technology in producing ultrasonically welded connections. This is due to increased process control, driving the limits of connecting different material combinations (e.g. for applications like power electronics and battery packs).

Smart Welders by Hesse, can precisely position a sonotrode to a product. An image recognition system determines the exact weld location very quickly and accurately, based on a derivation of an optimal trajectory. Together with long and narrow sonotrodes, this allows small pitching and compact products/higher power density.
Further advanced functions include touchdown sensing, precise and dynamic contact force control, diverse process control features such as monitoring of ultrasonic characteristics and deformation (ref. DVS 2811), and standardized interfaces for assembly line integration.

Smart Welders can, like ultrasonic wire bonders, flexibly handle a large variety of products. New products only require a program change and possibly adapted clamping and automation.

Advanced features and process advantages

  • Fully automatic ultrasonic welder with a very large working area
  • Image recognition for detection and correction of weld locations
  • Active vertical axis
  • Rotational p-axis for angle optimized process results
  • Wide range of ultrasonic (US) power
  • Ultrasonic welding as cell contacting system for battery applications
  • Narrow pitch and deep access due to long, narrow sonotrodes and pattern recognition supported positioning
  • Zero gap is performed by touchdown process not by clamping
  • Touchdown sensor to avoid damage to sensitive contact components
  • Precise and dynamic force control
  • Programmable welding maps with multi-interval processes
  • Individual parameters per weld
  • Flexibility to handle a large variety of products
  • Standardized interfaces for line integration
  • Automotive accepted process control (PiQC, patented)


  • Working area: max. 374 mm x 883 mm
  • Flexible use of the working area, e.g. vacuum clamping
  • Maximization of throughput by automation (two/more parallel lanes)


  • Process integrated Quality Control (PiQC): detection of further parameters, e.g. friction behavior, by additional sensor system for 100 % quality monitoring in real time (patented); as option
  • Full traceability of all relevant process data

Working area

  • Equipped with 400W weldhead:
    • X: 374 mm; Y: 857 mm; Z: 60 mm
    • P-rotation: 380°
  • Equipped with 1500W weldhead:
    • X: 374 mm; Y: 777 mm; Z: 54 mm
    • P-rotation: 380° centrally, 2 x 180° at travel range limits

Mechatronic weldheads

  • Weldhead for up to 400W
  • Weldhead for up to 1500W
  • Rotational p-axis head
  • Longitudinal transducer system
  • Electronically controlled weld force actuator
  • Precise touchdown control (force and speed)


  • Wide range of US power
  • Programmable ultrasonic power output
  • Programmable process profiles

Footprint and weight

  • SW1085: 880 mm x 1780 mm x 1912 mm, (W x D x H, excl. monitor and light tower), appr. 1800 kg