Transforming metal welding applications

The new Telso Terminal TT7 from Telsonic AG encompasses multiple latest generation technologies which together will transform ultrasonic metal welding applications for a wide range of industry sectors. Throughout the development of this innovative system, the specific requirements of different market sectors were evaluated and taken into account to ensure the highest levels of performance, versatility and efficiency across the widest range of applications.

The new TelsoTerminal TT7 ultrasonic metal welding system can be used for a broad range of tasks, including cable assembly and battery production. Current applications, where this high-performance system excels, include HV cables, battery connections and cell connectors that are welded in a diverse selection of designs. A key feature of the TT7 is its modular structure which enables quick re-configuration for other applications.

Based upon a compact and modern design, this modular system delivers a host of advantages including outstanding process control through the use of digital technology, standard interfaces for digital networking and easy integration into automation systems. The new system also incorporates the latest version of Telsonic’s proven PowerWheel welding technology as a standard feature, ensuring maximum reliability and optimum process control for welding metal cable cross sections up to 200mm2.

PowerWheel welding technology uses an innovative concept to vibrate the sonotrode, which is excited in a torsional manner. With scalable welding power of between 7.2kW and 14.4kW, the optimum welding power can be selected for each application.

Welds can be produced up to 30% narrower and higher compared to those produced by a linear system. This can often result in considerable savings in material and the space required to produce welds. A further benefit is that thicker terminal connections can be welded with great strength. The welding takes place in a swaying and rolling motion directly above the weld area. As a result, the maximum amplitude is always in the centre of the welding area and the energy is directed and focused within the welding zone. Telsonic’s PowerWheel standardised sonotrodes are optimised for copper and aluminium wires, meet the requirements of OEM's and harness makers, as well as the USCAR 38 standard (Performance specification for ultrasonically welded cable terminations). As with conventional ultrasonic welding, the PowerWheel® system can weld all non-ferrous metals.

Telsonic’s new QuickChange system makes it possible to exchange tools on the TT7 in less than five minutes. In addition, self-centring and positioning (Poka Yoke) of the PowerWheel sonotrode eliminates the possibility of error whilst greatly reducing any adjustments which may be required. Welding amplitude can, if required, be optimised for individual applications by means of a booster.

The TT7 system incorporates Telso Flex, the sophisticated control software used to monitor and log each application and operation. Within a production environment it is likely that there could be multiple changes in the part types being produced. Telso®Flex reduces the potential for errors during changeover through the use of a comprehensive application changeover checklist which provides clear step by step instructions for the operator.

Each step is described using a combination of text and images and the instructions fall into two categories – either a simple task or question or verification of application specific information. For example, the part number of the sonotrode being used must be entered and recorded for verification. Production can only begin upon successful completion of all changeover steps. If any steps are overlooked, the operator will be prompted to revisit and complete that step. Unauthorised changes are prevented with user and rights management for three user groups.

During production, Telso Flex offers various functions that ensure the highest levels of quality and productivity through continuous quality monitoring. These quality checks begin at the outset, when the terminal and wire are being clamped. If the clamp detects a difference in height, for example due to thickness variations or the clamp operating on just one side, the operator will be alerted to the error, and it will not be possible to initiate the welding process. The same is true should the wrong diameter of wire be detected during the clamping process.

The system detects trends that can be used to quickly detect and prevent possible production errors. Weld limits and results are shown both as numerical values and graphically as coloured bars, with blue representing values within limits, yellow as close to limit and red as outside of specified limits. The welding curves for power and distance are also displayed. All welding results, machine events, parameters and data are saved for traceability and analysis purposes. This data can then be exported from the controller via USB and Ethernet. In addition, the software presents operators with valuable information and topic-related assistance which reduces unproductive time during maintenance and service procedures.

The intuitive 21.5” capacitive touchscreen interface ensures that operators have all relevant information available to them at a glance, and with the Equipment Manager feature looking after acoustics and wear parts, which clarifies which components are on the machine, operation is made even simpler. In addition to the comprehensive standard specification of the new TT7, a range of options are available to suit individual customer requirements. These include wire strand stop with position detection, wire clamping for single or multiple cables and a bad part cutter to destroy parts where welds are deemed out of specification.

Liquid cooling and heating is used to adjust the temperature of the tools, keeping them within the optimum temperature range. The system software continually monitors the temperature and can stop production, protecting the system from overheating as a result of incorrect parameter setting etc. This feature, unique to Telsonic, not only minimises any variations between welds but also shortens the weld cycle, improving overall efficiency.

The new Telso Terminal TT7 can also be easily connected to customer’s MES (Manufacturing Execution Systems). The Telso Con interface provides a flexible solution for the interface of the TT7 via OPC-UA. This allows production orders and technical parameters to be transferred and shared over the network. Users are also able to access real time production data and welding results at any time and save this to network drives or other storage media.

With the system enclosure designed for easy access for maintenance or changeover procedures, this
fast, efficient, high-performance and low energy system will be welcomed by both existing customers and new users alike.

Summary Benefits

The new Telso Terminal TT7 ultrasonic metal welding system is versatile and can be used for various applications, including cable assembly and battery production. Among other things, its applications include HV cables, battery terminals and cell connectors, which are welded in a wide variety of designs.

Telso Terminal TT7 highlights

Outstanding process control

Wide range of applications, large cross sections

Short cycle time, high productivity,

New design for the PowerWheel

Easy integration into production lines

Telso Flex digitalization