Ultrasonic metal weldingfor power electronics and cell contacting systems

About us Power electronics / cell contacting systems

Our 300 employees worldwide develop and produce innovative ultrasonic welding machines - and,

together with our representatives, are always close to our customers. In addition to our headquar-

ters in Wettenberg (Germany), we have locations in Graevenwiesbach (Germany), Boston (USA), Mo-

scow (Russia), Kenitra (Morocco) and Taicang (Jiangsu Province, China). We also have a global sales

and service network.

ultra fast. ultra strong. ultrasonic.

Ultrasonic welding in the field of power electronics

In the field of power electronics increasingly high-performance

modules such as IGBTs (Insulated-Gate Bipolar Transistors) or IPMs

(Intelligent Power Modules) are produced with the help of ultrasonic

welding. Ultrasonic welding of the load and control connections to

substrates (e.g. DBC) offers full process and quality monitoring com-

pared to conventional soldering.

In reliability tests, ultrasonically welded power modules last up to

ten times longer. The intermetallic connection leads to a significantly

reduced power dissipation at the contact points, which increases the

electrical efficiency of the module and minimizes the cooling effort.

Cooling Technology Innovations

¬ Copper tubes

for refrigeration

circuits

¬ Capillary tubes

for thermostats

¬ EX-certified

¬ Cutting

¬ Punching

¬ Welding of plas-

tics and textiles

¬ Cut & Seal by

combined pro-

cedure

Service

¬ Technical advi-

ce and support

¬ Process de-

velopment and

integration

¬ Software

development

¬ Training system

Wire Harness

¬ Wire / Wire

¬ X-/Y-Splices

¬ Cascade

¬ Ground and

high current

contacts

¬ Busbars

Battery

¬ Battery modu-

les

¬ Li-Ion Techno-

logy

¬ Capacitors

¬ Anode/cathode

connections

¬ Copper/Tab con-

nections

DS20-S-plus FX20-L

DS20-S-plusThe manually operated ultrasonic welding machine DS20-S-plus is based on

a flexible concept and is suitable for laboratories, prototypes, sample series

production and smaller series production of e.g. power electronics, cell con-

tacting systems or special applications.

i

FX20-LThe FX20-L is a semi-automated ultrasonic welding machine for production. It is suitable for wel-

ding power electronic modules (e.g. IGBT modules) or cell contacting systems (battery applications).

The machine is available with a pattern recognition system for checking and correcting the welding

position and an external particle cleaning system.

¬ Ultrasonic welding head: 20 kHz (35 kHz available on demand)

¬ Working area: x-axis: 250 mm, y-axis: 400 mm - turntable: 360°

¬ special stiff axis systems resistant to ultrasonic vibrations

¬ Accessibility z-direction: max. 62 mm - special long welding tool available

¬ Ultrasonic welding head: 20 kHz (35 kHz available on demand)

¬ Working area (x-y-table): x-axis: 100 mm, y-axis: 250 mm (manually with crank handles)

¬ special stiff axis systems resistant to ultrasonic vibrations

¬ Accessibility in z-direction (sonotrode): max. 62 mm

All machines are equipped with a quick-change system for welding tools and a

patented dynamic process monitoring system. The latter monitors the power and

height curves and provides adjustable tolerances for welding time, height, energy

and deformation for each welding spot.

i further information

FX20-2L-RThe FX20-2L-R is a flexible and fully automated ultrasonic welding machine for

welding power electronic modules and cell contacting systems. Numerous options are available for

the machine, such as an internal particle cleaning system, robot loading and component feeding via

conveyor system.

Specifications

FX20-2L-R Specifications

¬ Two ultrasonic welding heads: 20 kHz (35 kHz available on demand)

¬ Working area (two x-y-tables): x-axis: 250 mm, y-axis: 600 mm. The highly reliable and precise

axles are equipped with a brake system that ensures maximum stability during the welding pro-

cess. The axle system is also designed to withstand ultrasonic vibrations.

¬ special stiff axis systems resistant to ultrasonic vibrations

¬ Accessibility in z-direction: max. 62 mm - special long welding tools available

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nce

i further information

Schunk Sonosystems GmbH

Hauptstrasse 95

35435 Wettenberg

Germany

+49 641 803 0

sonosystems@schunk-group.com

www.schunk-sonosystems.com

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