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WeldMAX™ Ultrasonic Spot Welder

Overview
Sonobond’s WeldMAX Model MH-15100 is the industry’s most powerful ultrasonic spot welder, delivering up to 10,000 watts of output power to weld a variety of metal assemblies.

The model MH-15100 produces ultra-reliable, solid-state metallurgical bonds without the use of heat, current, fluxes, filler materials, or other consumables. It creates a welded joint that is strong and highly conductive. And while the welding rate depends on the thickness and type of materials being joined, most operations are completed in less than 3 seconds.

The MH-15100 consists of a solid-state frequency converter, a welding head, with Sonobond’s unique Wedge-Reed system, and an easily removable and replaceable Taper Lock Tip which vibrates to ultrasonically spot weld the materials. Sonobond custom designs tooling to meet each customer’s specific needs.

Applications
The Sonobond WeldMAX Model MH-15100 ultrasonic welder is used for heavy gage wire to wire, or wire to terminal assembly, electrical bus bar fabrication, and other electronic/electrical assemblies even tinned stranded wire assemblies.

Theory of Operation
The WeldMAX MH-15100 uses Sonobond’s unique Wedge-Reed coupling system of high vibratory force and low amplitude to ensure precise, dependable welds. The unit directs high frequency, ultrasonic energy via a welding tip to the surface between the metals to be welded. The vibratory energy disperses the oxides and surface films between the workpieces and creates a true metallurgical weld without melting the materials.

Materials
The WeldMAX MH-15100 can be tooled to join stranded copper wire to wire up to 200 sq. mm. cross sectional area or equivalent weld area for stranded copper wire to terminal.

 

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Sonobond Ultrasonics, Inc.

1191 McDermott Drive West Chester, PA 19380

Features

  • Outputs 10,000 watts of power to weld nonferrous and dissimilar metal assemblies, including copper, aluminum, nickel
  • Produces ultra-reliable, solid-state metallurgical bonds without external heat or current
  • Requires no fluxes, filler material, or other consumables
  • Unique Wedge-Reed coupling system assures precise, dependable welds and facilitates special tooling, fixtures, rotary tables, or feeders
  • Heat-treated, tool steel Taper Lock Tips perform up to 50,000 welds and are easily removed and replaced
  • Minimal operating and training costs
  • Little or no pre-cleaning required
  • Energy efficient
  • Can be incorporated into automated assembly equipment
  • Automatic frequency control for stable operation

Tech Specs

ComponentWelding Head
ModelMH-15100
ControlsContact Sales Associate
AcousticsUnique Wedge-Reed and Contra- Resonant anvil system for high clamp force, low amplitude welding of metals
AirClean, dry air at 80-100 psi
ConstructionNEMA 12 panel enclosure with modular, easily removable sub-assemblies
Size (approx.)48" high, 20" wide, 34" deep
Weight (approx.)1,700 lbs.
WarrantyOne full year against defects in material and workmanship
ComponentPower Supply
ModelFC-15100
Output Power0 to 10,000 watt into 50 Ohm load
Frequency Range14.5 kHz to 16 kHz
Input Power480 volts, 50/60 Hz, 3 phase, 20 amps
ConstructionNEMA 12 panel enclosure with modular, easily removable sub-assemblies
Size (approx.)42" high, 24" wide, 12" deep mounted on 12" legs
Weight (approx.)150 lbs.