Automated Systems
Tech-Sonic works with customers to meet their manufacturing goals by providing semi and fully automated machines incorporating the use of our Falcon-20, -35 and -40 Ultrasonic Spot Welders and the Falcon-SM Seam Welder System. We currently offer two automated speciality welders: our Ring Termination Machine and Armature Welding Machine (see below).
Tech-Sonic welding machines deliver all the advantages of ultrasonic welding. They join 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 costs and is environmentally friendly because there's no need for consumables, such as solder, flux and crimps, and there's a low energy requirement
Automated Ring Termination Machine
This 20 kHz ultrasonic welder connects wires to ring terminals ranging from 1 mm to 13 mm wide. Specifications are:
- 3.0 kW maxium output
- 200-240 VAC - 50/60 HZ voltage supply
- 16 ampere maximum
- Requires 5.5-6.5 bar dry, clean air
- Size: 250 kg / 550 lbs
47"x47"x72" /
1200mm x 1200mm x 1800mm
Ultrasonic Armature Welding Machine
An armature has unique electrical manufacturing demands that can be met by Tech-Sonic's 20 kHz semi-automated Armature Welding Machine. |
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The armature is the power-producing component of an electromechanical machine (an alternator, generator, dynamo or motor). It carries electrical current and generates electromotive force.
Here’s how Tech-Sonic’s ultrasonic welding compares to the traditional resistance welding processs on an armature:
- Ultrasonic welds co-mingle the component’s atomic structures, resulting in welds as strong as the original components; the heat and melting required by resistance welding can result in brittle welds.
- The co-mingling of atomic structures in ultrasonic welding produces far superior conductivities than resistance welding.
- Excellent weld quality is obtained by using the Generator's Energy and Distance control modes. TheTech-Sonic Generator delivers the same weld time after time.
- The tooling life of our ultrasonic welder is typically much longer than the electrode life of a resistance welder.
- Ultrasonic welding requires far less electrical energy than resistance welding.
- Manufacturing costs of a commutator, the armature's internal electrical switch, are slashed in half when ultrasonically welded versus resistance welded. Resistance welding requires that the design hold the wires during the weld; with ultrasonic welding, the tooling holds the wire stationary. The resulting simplified design of the commutator saves about $1.50USD per commutator.
 
Resistance-welded armature
and commutator, right;
simplified design for
ultrasonic welding, far right
Tech-Sonic Armature Machine Specifications:
- Exceptionally quick welding time of less than one second
- 3.0 kW maxium output
- 200-240 VAC - 50/60 HZ voltage supply
- 16 ampere maximum
- Requires 5.5-6.5 bar dry, clean air
- Size: 200 kg / 441 lbs
47"x47"x72" / 1200mm x 1200mm x 1800mm
Sample Welds
Please send the components of your application to us. We’ll evaluate and weld them in our applications testing lab and recommend the correct type and size of ultrasonic welder for you application. 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.
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