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Ultrasonic wire splice solutions

24 April 2017

Specialist manufacturers and suppliers of components such as wiring harnesses are increasingly turning to Telsonic’s ultrasonic wire splicing technology as an alternative to more traditional methods of joining wires. In this article, Telsonic’s Martin Frost explains why he believes the shift to ultrasonics is occurring and the benefits that can be realised

For many, the traditional methods of joining or splicing wires have been soldering or resistance welding. These well-established processes have proven to be a reliable and trusted solution to many applications. Resistance welding is still often the preferred solution in applications where stainless steel or nickel are being used, or where the wire bundle may be very small. The potential drawbacks from the resistance welding process however include the heat generated, which may have an adverse effect on the mechanical properties of the material being joined, and high electrode wear which requires regular attention from operators or maintenance personnel.

Whilst soldering is a good solution for many applications, there are limitations to this process. These include difficulty in maintaining tight control over the process in a production environment, and the fact that when in service within areas where temperatures may become elevated, there may be a risk to the overall integrity of the joint. 

Ultrasonic splicing technology is increasingly finding its way into new applications, especially within the automotive and other industry sectors, where reliable electrical connections are required. The advantages of the ultrasonic splicing include lower contact resistance, high resistance to corrosion and the fact that the process is highly cost effective. Typical applications are splicing of stranded copper wires in sub-assembly operations, final assembly for wire harnesses or compaction of single wires. In addition, aluminium and copper aluminium combinations can be welded in the same machine using special tooling. To meet the increasing demand for its ultrasonic splicing technology, Telsonic has produced a comprehensive range of systems and solutions. 

The range starts with TelsoSplice TS3, a sophisticated wire splicing system. With a capability of splicing from 0.26 to 40mm² cross section wires and with a lightweight and compact design, it is suitable for use as a portable unit on wire harness assembly boards. This same weld head can also be used for sub-assembly operations and is available in various bench top and stand configurations. TelsoSplice TS3 is programmed and controlled through a touch screen monitor with an intuitive user interface. Individual welds and sequences can be easily defined and recalled. Various welding modes and quality windows can be configured with minimal effort. The weld quality can be ensured with multiple user levels and ­ just-in-time statistical analysis. Thanks to the networking capabilities, easy data exchange and integration into Management Execution Systems is possible. The system incorporates an easily maintainable horn and anvil mechanism, designed for high volume production on copper, aluminium or combinations of both.

The TelsoSplice TS6 is an advanced wire-welding machine designed for applications on larger cross sections. Thanks to its rugged construction it is possible to weld a wide range of cross sections, from 2.5 to 100mm², depending upon the material being processed. The weld head and the associated control system are also integrated into an ergonomic table. Typical applications for TS6 are wire connections with large cross sections, such as for high voltage, battery and drive cables. Aluminium and copper-to-aluminium combinations can also be welded within the same machine using special tooling. TelsoSplice TS6 also uses the common touch screen monitor and intuitive user interface, allowing easy transition between the different systems for operators and maintenance personnel.