Precise low force ultrasonic welding

Battery management systems (BMS) for cylindrical cells so far have been assembled by using resistance welding or laser welding, both of which have challenges in the production process. With the rising demand due to e-mobility, producers are looking for alternatives.

Driven by the market, Herrmann Ultraschall, Karlsbad, Germany, has developed the ultrasonic spot welder series HiS VARIO B. The new 35 kHz module suits especially the welding of BMS to small cylindrical cells and finest materials, which require precisely adjustable low weld forces. A new rocker design enables the system to balance the drives thus allowing for precise and reproducible weld forces as low as 5 Newton. 

When welding NF-metals ultrasonically the weld tool (sonotrode) changeover and the subsequent production restart cost valuable time. The welder has been re-designed to make sonotrode changes within a few minutes possible, including an indexed tool change system and inline accessibility from all sides. This reduces standstill times considerably.

With a module width of 69 mm and the option to position the welders tightly side by side, the HiS VARIO B 35 kHz offers industry-leading compactness and the small footprint machine-builders wish for. The VARIO control technology supports visual process monitoring, quality surveillance, and data acquisition – from small volume assembly to fully automated production processes.