Hesse Mechatronics

Smart Welder SW1089

Smart Welder SW1089 – Ultrasonic Welding Machine with large, fully accessible working area – for terminals, pins, copper rivets and sleeves

Smart Welders combine the best of two technologies:

The force and ultrasonic power of ultrasonic welding equipment
and
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.

Features and process advantages Technical data Applications Brochure

Previous Next

Fully automatic ultrasonic welder with a very large working area up to 392 mm x 870 mm
Welding of terminals, pins, copper rivets and sleeves using different sonotrodes and machine setups
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)

Flexibility

Flexible use of the working area, e.g. vacuum clamping
Maximization of throughput by automation (two/more parallel lanes)

Quality

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

Mechatronic weldheads

Rotational weldhead

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)

Material specifications

Typical material specifications for aluminum and copper.
Other parameters as in the below mentioned overview are possible, but require prior individual clarification of data such as material, geometry, objective and other application specifics.

Welding of …	Terminal		Pin/Rivet/Sleeve
Material	Thickness (Z) [mm]	Area (X x Y)[mm2]	Collar-Ø (d) [mm]	Thickness (z)[mm]	Length (l) [mm]
Cu	0,2 – 1,2	1,0² – 3,5²	1,5 – 2,5	0,1 – 0,5	3,0 – 18,0
Al	0,5 – 1,2	1,0² – 4,0²	–	–	–

Working area

Smart Welder	X	Y	Z
SW1089 – 400W	392 mm	870 mm	50 mm
SW1089 – 1500W	392 mm	870 mm	50 mm

Footprint and weight

Smart Welder	W x D x H [mm]	Weight
SW1089	930 x 1823 x 2040	ca. 2100 kg
excl. attached parts like e.g. status lamp, control panel etc.

Media connectivity

Power supply 100-240VAC
Gigabit-Ethernet (TCP/IP)
USB-Ports
HDMI
Compressed air (CDA clean, dry air)
Vacuum

Welding of terminals, leadframes	Welding of pins and sleeves
Contacting system for aluminum and copper; typical use for batteries and power electronics High speed, precise process control and highest accuracies in the field of metal welding with ultrasonic High current Low resistance	Direct copper-to-copper connections of pins, rivets and sleeves in power electronics Production process at room temperature, therefore no thermal impact Repair capability Enhance existing sintering process steps due to unnecessary soldering process Better thermal conductivity Higher thermomechanical stability Beneficial for product lifetime

Applikationen und Anwendungsbeispiele

Terminals on Power Moduls	Terminals on Battery Packs	Sleeves on DCB
Terminals Copper Pins Leadframes e.g. welding of Cu leads on DCB (inverter) Power Pins Sense Pins Flex PCB to PCB	Cell contacting system for battery cells, battery modules and battery management system (BMS) Current-carrying contacts (e.g. from cell to busbar) Contacts for cell voltage monitoring (e.g. BMS) Other electrical connection for connecting cells and measuring voltage e.g. welding of Hilumin® leads on hilumin® (battery) Al Leads on Al (battery) Al Leads on Hilumin® (battery) Al on ENIG/ENIPIG (BMS)	Direct copper to copper connections with superior reliability Post process after sintering without influencing pre processes Unique flexibility in pin layout due to programmable position of every single pin Flexible use of pin material (solder pin, different press-fit pins) Increased yield due to superior tolerances (even for soft solder die-attach) e.g. welding of Cu sleeves on DCB (power modul, IGBT-modul) also for similar applications

Download Brochure

Please complete the request form using the button and enter your name and business e-mail address. A download link will be sent to you after verification.

Download Request Smart Welder