Digital Servo Spot Welder US-3020S U.S. Patent Pending

The World’s First ServoUltrasonic Spot Welder

FrequencyUltrasonic Power

Output

Weld ForceWeldhead

Controller Cabinet

Visual DisplayAdditional

Options

20 kHz nominal3.0 kW max Power Supply 205-240 VAC single phase; 20 Amp max; Nema 6-20r outlet~5,500 Newton maximum59 kg / 53.3 x 50.8 x 25.4 cm 130 lb / 21 x 20 x 10 inches33 kg / 50.8 x 70 x 22.9 cm 71 lb / 20 x 24 x 9 inches

17 inch LCD display and mouse

Table / Touchscreen Monitor Barcode Scanner

Specifications

Standard Model US-3020S

Heavy Duty Upgrade US-3020SH

Material Type

Cu & Al Foil Welding Foil to Tab Foil to Busbar Tab to BusbarOver 100 Layers Cu & Al Foil Welding Foil to BusbarNon-ferrous Copper (Cu) Aluminum (Al)

Welding Capabilities

Dynamic Force and Amplitude Control™ with Multi-Step Welding

• Ability to adjust force and amplitude during the weld cycle to optimize parameters for each specific wire application

• Capability of over 20 weld steps with unique force and amplitude parameters while energy and frequency remain constant

Load Cell Force Feedback• Single micron resolution• Consistent measurement and ultrasonic output produce

high cPk values• Measurement of pre-weld and post-weld height

Doc#B10030

Network Compatible• Logs weld height, weld energy, & weld time• Saves last 20,000 welds; export via USB or TCP/IP

Industry Leading Missing FoilDetection Under 3% CSA

• System can detect one missing or one additional battery foil from a stack of 60 copper or aluminum foils

TECH-SONIC offers comprehensive multi-national support and service!

United States, HeadquartersColumbus, Ohioinfo@techsonicultrasonic.com

MexicoCiudad Juarez, Chihuahuarosendo@techsonicultrasonic.com

IndiaJanakpuri, New Delhisushant@techsonicultrasonic.com

PhilippinesBasak, Lapu-Lapu Citydante.d@techsonicultrasonic.com

China (Shenzhen)Nanshan, Shenzhen, Guangdongtsc@techsonic.com.cn

China (Suzhou)Industrial Park, Suzhoutsc@techsonic.com.cn

GermanyObertshausen, Germanyk.bauer@techsonicultrasonic.com

ThailandBang Na, Bangkokatthapol.c@techsonicultrasonic.com

Website www.tech-sonic.us

Address 2710 Sawbury Blvd.

Columbus, OH 43235 USAPhone

+1-614-792-3117Email

info@techsonicultrasonic.com

Doc#B10030

Versatile Solutions in the Battery, Wire Harness, Automotive

Manufacturing, Medical, and Defense Industries

TECH-SONIC has been providing industry support on a Multi-National level for over two decades

Multi-Step Welding: this teach screen displays the ability to utilize multi-step welding with variable force and amplitude

control. The first-step is a compression stage without ultrasonic energy, followed by the changing of parameters over the next three steps, and a final compression stage to US-3020S Ultrasonic Controller Cabinet

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Servo-Controlled Ultrasonic Welding of Tabs and Foils in Lithium Battery Assembly

TECH-SONIC is the first manufacturer to develop a highly-advanced servo-controlled ultrasonic metal welder, including spot welders for lithium battery assembly. It combines the latest technologies in ultrasonic welding, servo control, user-friendly microprocessor control, and load cell force feedback, providing a 100% digital welding process.

Having been involved in lithium battery welding since 1996, TECH-SONIC has been working with many of the leading battery manufacturers of the world over twenty years of operation. With long established expertise in lithium battery welding, TECH-SONIC has been working with these manufacturers on new advanced solutions in welding foil stacks, foil-to-tab, foil-to-busbar, and tab-to-busbar (see figures 1 & 2) to meet the needs of assembling current and future batteries.

TECH-SONIC has gone beyond the latest ultrasonic metal welding technology by adding servomechanism control to ultrasonic welding, thus producing a full digitally controlled welding process that responds to the various dynamics of today’s critical welds. Servo ultrasonic spot welders provide accuracy, repeatability, and reliability, especially in the welding of copper or aluminum foils which are a base material as anode and cathode in lithium battery designs. This patent pending line of machines allow for Dynamic Force and Amplitude Control™ coupled with multi-step welding to create the optimum welding parameters for the often-challenging foil and tab welds.

With single-micron resolution linear encoder, servo ultrasonic welders are able to detect weld height changes relative to a set tolerance window with greater precision an accuracy than their pneumatic counterparts. For example, TECH-SONIC’s 3.0kW servo spot welder, model US-3020S (figure 3), can detect one single missing or added foil in a stack of sixty (the thickness of a foil is around 8-10um) and signal the error to the user before initiating the welding sequence. Typical pneumatic welders do not have missing or added foil detection capability with such precision.

Figure 1. Small size lithium battery for portable devices Figure 2. Large size lithium battery for EV

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By compressing the foils or tabs being welded with soft touch landing of the ultrasonic horn (sonotrode), servo ultrasonic welders can reduce or prevent foils breaks and cracks by reducing stress and allows no coating damage by ultrasonic vibration. Often in pneumatic processes, the top layers of foils are cracked by the violent descent of the horn.

Figure 3. US-3020S Servo Ultrasonic Spot Welder

Conventional pneumatic ultrasonic metal welding machines also require larger, bulkier parts to support the high force produced by the pneumatic cylinder during welding. Such high force requires increased amounts of power of 5.0kW or more to create necessary friction between parts. Higher power also introduces additional stress and wear on the tooling which increases likelihood of horn cracking damage and decreases tooling life. TECH-SONIC tooling can extend life cycles depending on material thickness and the size of the horn by minimizing power requirements and optimizing the amount of energy and force needed to create solid bonds.

The use of optimum force and energy though Dynamic Force and Amplitude Control™ open opportunities for end-users to weld larger stacks of foils with a wider weld area (due to a wider horn). Welding stacks of foils or tabs to busbar is also possible while maintaining the same power requirement and limiting the amount of rifts surrounding the weld area caused by ultrasonic vibration.

For delicate applications, TECH-SONIC also has a 900W servo ultrasonic welder, model US-935S. This machine possesses many of the same features as its 3.0kW companion in a scaled down version to weld with much smaller delicate parts. It is able to detect single missing or added foils and tabs in a stack and has a smaller weld area for precision welding. The lower power and higher frequency make this the ideal solution for batteries used in mobile phones, credit cards, and other small devices.

TECH-SONIC servo ultrasonic welders include simple, automatic calibration mechanism for ideal repeatability and accuracy. The machines are based on the reliable Windows CE operating system and can provide TC/IP interface for transfer of production information to a host system via USB, where it can be saved and analyzed.

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TECH-SONIC, Inc. is headquartered in Columbus, Ohio, with subsidiaries in China, and sales and service offices in Mexico, Germany, India, Thailand and the Philippines. It has been designing and manufacturing high-tech ultrasonic metal welders since 1996. In recent years, the company has devoted its research and development to servo controlled ultrasonic metal welding – the “Holy Grail” of ultrasonic metal welding. As a pioneer in servo ultrasonic metal welding technology, TECH-SONIC integrates the latest electronics, hardware, location and force sensors, and control software in new and unique ways.

TECH-SONIC has been serving global companies in electrical, automotive, EV, battery, wire harness, appliance, HVAC, solar, and military industries throughout the world, and in addition, its engineers have many years of experience in custom welding systems. To demonstrate that TECH-SONIC equipment can meet your welding needs and assembly specifications, the company provides free welding sample testing. For more information and to apply for free sample testing, please visit our website www.tech-sonic.us. For immediate assistance, call Frank at +1-614-792-3117 or email info@techsonicultrasonic.com.

Servo Spot Welder Demo Video Links

US-3020S Servo Spot Welder Demo US-3020S Servo Spot Welder Demo (Alt)

US-3020S 50mm² Spot Weld Demo US-3020S 50mm² Spot Weld Demo (Alt)