Tech-Sonic’s industrial, ultrasonic wire splice solution, the Falcon-20W, welds stranded, braided and magnet wires with diameters / cross sections from 0.5 mm to 28 mm, or three gauge to 20 gauge. The wire bundles it produces are used for the automotive, aircraft, computer and consumer electronics industries, and for other process control and industrial instrument applications. It's most commonly used in the production of wire harnesses.
Footprint: 7.5" x 18"
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The Falcon-20W delivers all the advantages of ultrasonic welding. It joins copper and aluminum wires in strong, lasting, metallurgic welds. The bonds are typically stronger than soldered- or resistance-welded joints, are high in conductivity, and do not oxidize.
Ultrasonic welding lowers production cost and is environmentally friendly because there's no need for consumables, such as solder, flux and crimps, and there's a low energy requirement
About the Falcon-20W
Splices stranded, braided and magnet wires
Wire Splice range: three gauge to 20 gauge 0.5 sq mm to 28 sq mm
Meets requirements of automobile manufacturers
Welding time is within one second
Precision adjustment of splice width
Easy wire load and unload
Solid tooling design for consistent welding and long tool life (no tip required)
Tooling welding surfaces have a rough diamond-pattern surface to prevent slippage
Competitive initial cost and low cost for replacement tooling
Bench top unit is a lightweight, compact, modular system ideal for limited-space areas
Ease of Use
Uniform weld quality guaranteed through constant welding parameters integrated into the system
Skilled operator not necessary; training done on-site within a day
Fast & easy tooling changes without recalibration reduce downtime and operating costs
Easy set up, maintenance and operation
The Falcon Generator offers:
Integrated quality control system with automatic process monitoring ensures seals within pre-set quality parameters of weld energy, time & height
Automatic calibration and frequency tuning adjustment
Adjustable tolerance
Electronic pressure regulator
Automatic sequential welding
Digital amplitude control for precise setting (+/- one micron)
Automatically adjusts energy
Preset welding parameter lookup tables
RS232 port for optional programmable logic controller (PLC)
Stores 999 weld programs
Password-protected system for high-level security
Sample Welds
Just provide the wires for your application. We’ll weld them in our test lab and suggest the ultrasonic application that best meets your needs. Request for Welding Test .
Specifications are believed to be accurate and provided as information only. However, no responsibility is assumed by Tech-Sonic Inc. for their use.
Wire Splice Welder
