Ultrasonic Welding

Training Documentation

The Quality Connection

Training Content Ultrasonic Welding (1)

Operator Technical Process

Service Owner
Fundamentals
Fundamental Terms Harness
Definition Ultrasonic Welding
Applications and Processes
Basic Structure of an Ultrasonic Welding System
Usage of Ultrasonic Welding Equipment
Advantages and Disadvantages of US Welding
Comparison of Connection Technologies
Welded Connections
Weldability of Materials for Ultrasonic Welding
Properties of Welded Splices
Equipment Parameters
Compression
Dimension Ratios and Degree of Compression
Symmetrical and Asymmetrical Splices
Design Rules for Ultrasonic Welded Splices
Equipment Parameter Determination
Typical Problems

Click on the name of the auditory (e.g. operator), to start the corresponding presentation!

PPE HQ Kitzingen / Training documentation Ultrasonic welding 2

Training Content Ultrasonic Welding (2)

Operator Technical Process

Service Owner
Process Flow
Safety Instructions
Demands on the Operator and Technical Service
Process Overview
Handling Instructions
Rework
Process Monitoring
Detectable Faults
Dynamic and Static Limits
Welded Splice Evaluations and Approvals
Fundamentals
Visual Inspection
Splice Measurement
Bending Test
Peel Force Test
Tensile Strength Test
Micrographics
Capability Approval of Splice Parameters
Click on the name of the auditory (e.g. operator), to start the corresponding presentation!
PPE HQ Kitzingen / Training documentation Ultrasonic welding 3
Training Content Ultrasonic Welding (3)

Operator Technical Process

Service Owner
Ultrasonic Welding Equipment
LEONI – Standard Equipment
LEONI – Legacy Equipment
Technical Details
Requirements to the Welding Equipment
Maintenance
Standards and Specifications
Customer Specifications
LEONI Internal Specifications
Work Instruction AA 3092
Final Test
Section 1
Section 2
Section 3

Click on the name of the auditory (e.g. operator), to start the corresponding presentation!

PPE HQ Kitzingen / Training documentation Ultrasonic welding 4

Fundamentals –
Fundamental Terms Harness

strand wire / conductor cable splice

isolation stripping
concentric layout butt- / end splice

asymmetric layout
full strip inline splice

half strip

PPE HQ Kitzingen / Training documentation Ultrasonic welding 5

Fundamentals –
Definition Ultrasonic Welding

The ultrasonic welding is a method for Basic Principle

joining metallic materials (and plastics to start click in the picture
and thermoplastics).
With metallic materials it is used mainly in
aluminium, copper and its alloys.
The required heat is generated by a high-
frequency mechanical vibration which
arises from friction between the
components. Thus, the ultrasonic welding
is a form of friction welding.
In metallic compounds a durable, metallic
pure compound with good electrical
properties is formed in a short time,. The
strength of this connection is about 90%
of the strength of the base metal.

Micrograph of a
ultrasonic welded
splice

PPE HQ Kitzingen / Training documentation Ultrasonic welding 6

Fundamentals –
Applications and Processes (1)
Typical applications

Production of splices Welding of contacts

Connection of special components Ultrasonic compression

PPE HQ Kitzingen / Training documentation Ultrasonic welding 7

Fundamentals –
Applications and Processes (2)
Application sites of ultrasonic welding

Pre-assembly, contact welding Final assembly harness

Processes

Splice welding Sequence welding

Repeated welding of the same splice
Welding of a sequence of
or connector different splices / contacts

Splice is directly selected at the
Repeat the sequence at
machine the next harness

Sequence is defined in the
machine

PPE HQ Kitzingen / Training documentation Ultrasonic welding 8

 Fundamentals –
Basic Structure of an Ultrasonic Welding System (1)

Converter
Computer
Booster
Sonotrode
Anvil and
compression
area

Generator and
control system

Move the mouse over an object to

show details!

Converter
Computer
Anvil
Booster
Generator
and compression
Sonotrode and control system
area
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In
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PPE HQ Kitzingen / Training documentation Ultrasonic welding 9

Fundamentals –
Basic Structure of an Ultrasonic Welding System (2)

Computer The computer allows using a Windows software an easy operation of the
welding system. Thus, the connector cross-sections and the welding type
can be selected or created and stored. During welding the computer
monitors the quality of the process.
Generator and The generator converts AC voltage into an electrical signal as required by
control system the converter (1400 VAC / 20 kHz). To compensate interferences during
operation the generator is equipped with a controller that keeps the voltage
and frequency of the emitted signal constant.
Converter The converter changes the electrical signal from the generator into a
mechanical oscillation. For the conversion are used in industry today
electro-mechanical methods, especially piezoelectric transducers.
Booster The booster is used to increase or reduce the amplitude of the mechanical
vibration generated by the converter. Simultaneously, the booster is also
used for the bearing of the oscillator system in the machine.
Sonotrode The sonotrode is in reality the tool of the ultrasonic welding machine.
Depending on the geometric design of the parts to be welded, there are a
variety of different sonotrode forms, which differ primarily in the design of
the work surface.
Anvil and In the compression area the cable ends to be welded are compressed. The
compression anvil serves as an abutment for the sonotrode. The shape of the anvil
area
determines the shape of the welded splice.
PPE HQ Kitzingen / Training documentation Ultrasonic welding 10
Fundamentals –
Usage of Ultrasonic Welding Equipment
As stand alone application Integrated in production line

Integrated in cable cutting machine (e.g.

Komax Zeta)

PPE HQ Kitzingen / Training documentation Ultrasonic welding 11

Fundamentals –
Advantages and Disadvantages of Ultrasonic Welding

Advantages

Very good electrical properties

Good mechanical properties

Process monitoring and visualisation

Usage in production of customer specific harness (KSK) possible

Long life time of tools (sonotrodes)

Disadvantages

Tinned wires can not be welded

Contacts must be free of tin in the welding area

Relatively sensitive to contamination of the strands (e.g. perspiration from hands, fumes
from insulation)

PPE HQ Kitzingen / Training documentation Ultrasonic welding 12

 Fundamentals –
Process Comparison of Connection Technologies in Harness Production
Advantages Disadvantages Application area

• high rigidity
• low contact resistance
• better long time stability of the contact • relatively high heat input
• terminal welding
resistance • higher investment costs compared to
• compacting / splice welding
Resistance • relatively fault-tolerant (pollution, ...) pressing processes
• for safety related contacts
welding • low setup times • not suitable for assembly line integration
• compared to ultrasonic welding for smaller
• high cross section area weldable • very high energy costs (including cooling)
welding cross sections and single lines
• no additional material required (for splices) • no manual rework possible
• good process monitoring
• sequences can be welded

• high rigidity • requires defined environmental conditions

• low contact resistance (increased demands for cleanliness)
• better long time stability of the contact • higher investment costs compared to • terminal welding
resistance pressing processes • compacting / splice welding
Ultrasonic
• low heat input • high energy costs • for safety related contacts
welding • high cross section area weldable • Not suitable for tinned contacts / wires • compared to resistance welding for bigger
• no additional material required (for splices) • exact alignment of the sonotrode welding cross sections (often > 10 mm2)
• good process monitoring necessary
• sequences can be welded • no manual rework possible

• great experience and knowledge

• high material costs (terminal) • terminal contacting
• equipment well known and technically
Crimping mature
• critical in case of higher cable numbers • used with small limited number of cables,
• low cross section area per terminal usual single cable
• long term proven

• partially missing specification (processing

• experience and knowledge
according to crimping specification)
• equipment well known and technically • butt splices
Squeezing mature
• high material costs (terminal)
• ring terminals with large cross sections
• low cross section area per terminal
• long term proven
• no or very limited process control

Squeezing • high rigidity • almost double cycle time (compared to

• butt splices
• low contact resistance squeezing)
and • „compensation“ of squeezing process faults • high material costs (terminal and solder)
• terminal / ring cable eyelets
soldering • preferred large cross sections
by soldering => high process safety • doubled equipment

PPE HQ Kitzingen / Training documentation Ultrasonic welding 13

Welded Connections –
Weldability of Materials for Ultrasonic Welding

PPE HQ Kitzingen / Training documentation Ultrasonic welding 14

Welded Connections –
Properties of Welded Splices

Welded connections (splices) are characterized by various properties. These properties

determine the structure and the durability of a welded connection and are caused by the
construction of the connector (design), the settings of the welding system (equipment
parameters) and the operator.

Property Determined by …
number of cables to one (butt splice) or to both sides (inline design
splice)
cross section of the cables design

ratio of the cross sections of the cables design

splice width equipment parameters
splice height before welding design
equipment parameters
splice height after welding design
equipment parameters
degree of compression (compaction measurement) equipment parameters
symmetry operator

For each property, there are guidelines and limits that must be adhered to during
ultrasonic welding.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 15

Welded Connections –
Equipment Parameters

Parameter Unit Description

welding bar pressure with which presses the sonotrode on the anvil
pressure

splice width mm distance of the lateral boundaries of the compression

area during weldig process

amplitude % ???

energy Ws energy used for welding

PPE HQ Kitzingen / Training documentation Ultrasonic welding 16

Welded Connections –
Compression
Number of cables and its single cross-sections define the
structure of the node.

The cables and the set node width (B) determine the height
of the node before welding (H1).

H2

The cables, the welding energy and the pressure determine

the height of the node after welding (H2).

PPE HQ Kitzingen / Training documentation Ultrasonic welding 17

Welded Connections –
Dimension Ratios and Degree of Compression

B
The width-to-height ratio (B:H2) must be in the range of 1:1 (small
splaces) to 2:1 (large splices).
From the cross-sections of the cables and the dimensions of the
splice the compression ratio is determined:

sum of the real cross sections of the cables in the splice1

V=
splice width (B) x splice height (H2)

1 The real cross sections of a cable are determined according to AA

3044 by the quantity of the strands in a cable multiplied with the
cross section of the strands.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 18

 Welded Connections –
Symmetrical and Asymmetrical Splices

The symmetry determines the peel force of a splice. Therefore, the

splices must always executed asymmetric.

Peel force [N]

Symmetrical Asymmetrical
18 276
104 278
26 362
22 420
14 432
Symmetrical splice
30 272
20 376
64 352
44 390
24 262
Average: 37 Average: 342
Asymmetrical splice

PPE HQ Kitzingen / Training documentation Ultrasonic welding 19

Welded Connections –
Design Rules for Ultrasonic Welded Splices

The following design rules for ultrasonic welding splices are already in the development
of the cable set into consideration!

Maximum number of cables

at butt splices (customer specific): 8 – 15 cables

at inline splices: 5 cables to both directions
Largest Cable in Weld Area
Ratio of smallest and biggest Cable area
[mm²]
0,35 0,35 0,50 0,50 0,60 0,75 0,80 1,00 1,40 1,50 2,00 2,50 3,00 4,00 5,00 6,00 7,00 8,00 9,00 10,00

cross section of the cables Nº of strands

0,35
7 12-19 7 16-19 12 19-24 ------- 19-32 19-27 19-30 37 19-50 45 56-118 70 84-189 ------- ------- ------- 40-144
G G G G G G G Y R R R R R R R R R R R R
7

customer specific: 1 : 3 to 0,35

12-19
G G G G G G G Y Y R R R R R R R R R R
0,50
1:4 7
0,50
G G G G G G G Y Y R R R R R R R R R

16-19
G G G G G G G Y Y Y R R R R R R R

for possible cross section Smallest Cable in Weld Area
0,60
12
G G G G G G G Y Y R R R R R R R

combinations see table 0,75

19-24
G G G G G G G Y Y R R R R R R
0,80
-------
G G G G G G Y Y R R R R R R
1,00
19-32
G G G G G Y Y Y R R R R R

The smallest cable must 1,40

19-27
G G G G G G Y Y R R R R
1,50
have at least 5% of the total 19-30
2,00
G G G G G Y Y R R R R

G G G G G Y Y R R R
cross section of the splice 37
2,50
G G G G G Y R R R
19-50
3,00
45
G G G G G Y R R
4,00
56-118
G G G G G G G
5,00
70
G G G G G G
6,00
84-189
G G G G G
10,00
80-144
G

PPE HQ Kitzingen / Training documentation Ultrasonic welding 20

Welded Connections –
Equipment Parameter Determination

The equipment parameter

determination is made in
accordance with the annex 7
of the VA 3092.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 21

Welded Connections –
Typical Problems

Problem Root cause Corrective action

no or bad weldability fumes from insulation • increase the welding
of cables (plasticizers) lay on the copper energy up to 30%
strands and reduce the • clean the strands of the
weldability of the cables cable1
• complain the cables at
supplier
symmetrical splices wrong insertion of the cables • usage of insertion aids
• operator training

1 The cleaning of the strands with alcohol is not general solution. Tests
made with FLRT3 cables showed a reduced weldability after cleaning. In
FLRY lines, however, they will better.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 22

Process Flow –
Safety Instructions
Safety Instructions

Each person working on the ultrasonic welding system (installation, startup, setup,
operation, cleaning, maintenance, repair) must read and understand the complete
operation manual in advance.

Only instructed, trained personnel may work on or with the ultrasonic welding system. The
machine must only be operated with closed control cabinets, junction boxes, control
panels and protective devices.

Country-specific accident prevention regulations must be complied with insofar as they
are higher quality than the EU rules

Warnings in the operating instructions are clearly marked and must be observed under all
circumstances

New staff must fully trained in operation and / or maintenance

The teach mode / setup may only be accessible to authorized persons

PPE HQ Kitzingen / Training documentation Ultrasonic welding 23

Process Flow –
Demands on the Operator

Training, order and cleanliness

The operator has to be trained and authorized

Only one person is allowed to work on the system

Regularly clean workplace

All items that are not needed for work, must be removed

Safety

All access to the workplace must kept free

The emergency stop button must always be accessible

Protective devices must not be removed

PPE HQ Kitzingen / Training documentation Ultrasonic welding 24

Process Flow –
Demands on the Technical Service Engineer

Training

The technical service engineer has to be trained and authorized

Authority, responsibilities

Is authorized and trained to make changes
in teach mode

Is responsible for the safekeeping and use

of the key for mode selection

Is responsible for documentations in the machine specific file

Is responsible the intended use of the ultrasonic system

Is responsible for maintenance according to maintenance plan

PPE HQ Kitzingen / Training documentation Ultrasonic welding 25

Process Flow –
Process Overview

PPE HQ Kitzingen / Training documentation Ultrasonic welding 26

Process Flow –
Handling Instructions (1)

The anti-splice protection (half strip) may
only be removed just before welding

Correct

A smoothing of the strands is usually not
necessary and to avoid, twisting the strands
is not permitted
Incorrect

It is important to ensure absolute

cleanliness. Contaminants (such as oils,
greases, hand creams, etc.) must be
avoided.

Oi l

To avoid contamination by perspiration
finger protection or gloves can be used, but
are usually not necessary.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 27

Process Flow –
Handling Instructions (2)

The cables are straight and aligned parallel
to each other and as far as possible, vertical
(stacked) to insert into the compression
chamber. The distance to the insulation
should be 1-5 mm. Correct

To avoid brush of strands the cables must

be inserted in a way, that the strand ends
are within the tool.
Incorrect

Insulation shall not be clamped.

Incorrect

Strand overhang in inline splices as small
as possible, typically 0 - 2 mm.

Correct

PPE HQ Kitzingen / Training documentation Ultrasonic welding 28

Process Flow –
Handling Instructions (3)

The cable with the largest single cross section
has to placed on the sonotrode (bottom).

Correct Incorrect

For the compound of two cables the wires must

be positioned above each other.

Correct Incorrect

For cable combinations with symmetrical
design (e.g. 6 x 1.50 mm ²) increased attention
is required to a asymmetric placement, if the
wires can not be placed above each other.

Correct Incorrect

Existing insertion aids (Anti Splice Side Kit) are

to be used.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 29

Process Flow –
Handling Instructions (4)

Short, one sided crimped wires (less than 400 mm length, with sensitive terminal) are
bended by 90°(L- form) or double 90°(Z- form) to avoi d the danger of breaking terminals
by vibration. Sensitive terminals = all types that can be damaged by welding process.
Simple cable lug terminals are not sensitive. In the first-off-release at least 5 samples are
tested with higher energy-values (+30%).

Correct Correct

Incorrect

PPE HQ Kitzingen / Training documentation Ultrasonic welding 30

Process Flow –
Rework

Rework is only within the scope approved by the customer and with the procedures
approved by the customer possible.

Defective welds have be destroyed and shall not go into production.

Splices in the wiring harness can be reworked at sufficient length max. 3 times. In a
manual process the wires are stripped with released hand pliers or released automatic
equipment. It is making sure to cut no single wires. The welding process is repeated.

If the splice can not be reworked successful, the further procedure has to comply with
AA 3006.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 31

Process Monitoring –
Detectable Faults
The ultrasonic welding machines are equipped with a process monitoring that detects faults.
These faults can have different causes.

Fault Possible causes

height of the node before welding incorrect • Additional cable
• Missing cable
height of the node after welding incorrect • Cables can be due to contamination poorly
or not welded
• No welding due to system breakdown
Welding time exceeding • Cables can not welded

To detect faults the correct tolerances must be entered. The boundaries must be neither
too large nor too small.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 32

Process Monitoring –
Dynamic and Static Limits
The splice height detection is equipped with static and dynamic limits.

The static limits define the absolute upper and lower limits for the process. They are
essentially determined by the tolerances of the lines and the theoretical compacting
results. These static limits allow only a rough detection of faults, particularly in the
recognition of the absence of very small cables.

Therefore additional dynamic limits are defined. This is based on the fact that the good
results of several successive welds can not change abruptly, since the tolerances of the
cables are not changing abruptly, too. This allows the dynamic limits to be set much
closer together, enabling a significantly better detection of faults. The dynamic limits can
move between the static boundaries.

Upper static limit

Upper dynamc limit

Lower dynamic limit
Lower static limit

PPE HQ Kitzingen / Training documentation Ultrasonic welding 33

Welded Splice Evaluations and Approvals –
Fundamentals

Welded splices are approved according AA 3092

There are destructive and non destructive tests

non destructive tests:
• visual inspection
• splice measurement

destructive tests:
• bending test
• peel force test
• tensile strength test
• micrographs

PPE HQ Kitzingen / Training documentation Ultrasonic welding 34

Welded Splice Evaluations and Approvals –
Visual Inspection (1)

The following faults are inspected during visual inspection:

burrs

burr

max. width B < 0,2 mm

max. height H < 0,5 mm

wire too much outside the splice

wire too far inside the splice

PPE HQ Kitzingen / Training documentation Ultrasonic welding 35

Welded Splice Evaluations and Approvals –
Visual Inspection (2)

loose strands

insulation in the splice

splice welded with to much energy, discoloured

missing structure at the surface of the splice

PPE HQ Kitzingen / Training documentation Ultrasonic welding 36

Welded Splice Evaluations and Approvals –
Splice Measurement
Measuring the dimensions of welded splices is
carried out at:

huge validation

first equipment setup

requalification of equipment

maintenance (comparision with displayed
value)
The results are also used to calculate the
compression ratio.
Tolerance in a lot size / order is at:
• height: ± 0,05 mm
• width (Ø ≤ 8 mm²): ± 0,10 mm
(Ø > 8 mm²): ± 0,15 mm
Width measurement Height measurement

Due to burrs do not measure all

the surface!

Measuring at least 2 waves!

PPE HQ Kitzingen / Training documentation Ultrasonic welding 37

Welded Splice Evaluations and Approvals –
Bending Test

Execution

Fixture splice to welding zone. The wires are bended two times by 90°to the top and back
to the origin. The force is ignited 30 mm from the end of the welded splice.

2x

30 mm

Result

No single wire should break in this test, especially at the beginning of the welding zone.
Further on no loosening of single wires is allowed.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 38

Welded Splice Evaluations and Approvals –
Peel Force Test

Execution Tolerance of tensile strength and peel force for US welding

Peel force test is executed at butt slices. Lower Lower
For testing the peel force the wire with the tolerance limit tolerance limit
Cross section of pull force of peel force
smallest cross section (anvil side) is [mm²] AWG [N] [N]
pulled. The counter part of the tested wire 0,35 22 60 12
has a bigger cross section, if necessary
0,5 20 80 15
the counterpart may consists of more than
0,75 19 120 23
one wire.
0,85 18 135 28
1 17 160 35
1,25 16 180 40
1,5 15 200 45
2 14 225 57
2,5 13 250 70
3 12 280 80
4 11 350 100
5 10 420 115
Result
6 9 500 130

The minimal peel forces according to table
7 540 135
have to be reached.
8 8 600 145

The breaking zone should be in the middle
10 7 800 165
of the splice and not at the beginning.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 39

Welded Splice Evaluations and Approvals –
Tensile Strength Test
Execution Tolerance of tensile strength and peel force for US welding

Tensile strength test is executed at inline Lower Lower
splice. To avoid shear force the opposite tolerance limit tolerance limit
wire runs straight in line with no steps. For Cross section of pull force of peel force
testing the tensile strength the wire with [mm²] AWG [N] [N]
the smallest cross section (anvil side) is 0,35 22 60 12
pulled. The counter part of the tested wire 0,5 20 80 15
has a bigger cross section, if necessary 0,75 19 120 23
the counterpart consists of more than one
wire. 0,85 18 135 28
1 17 160 35
1,25 16 180 40
1,5 15 200 45
2 14 225 57
2,5 13 250 70
3 12 280 80
Result
4 11 350 100

The minimal pull forces according to table
5 10 420 115
have to be reached.
6 9 500 130
7 540 135
8 8 600 145
10 7 800 165

PPE HQ Kitzingen / Training documentation Ultrasonic welding 40

Welded Splice Evaluations and Approvals –
Micrographics
Execution

Micrographs are done at the position with the highest compression. This is usually the
middle nugget (medium groove). Otherwise the degree of compression differs from the real
achieved compression! At some splices a precise cut is difficult to achieve and its just one
position of the total splice length – this is taken into account when evaluating micrograph.

Result

Assessment of micrographics ??

PPE HQ Kitzingen / Training documentation Ultrasonic welding 41

Welded Splice Evaluations and Approvals –
Capability Approval of Splice Parameters – Huge Evaluation

Execution

Schedule:
• after determination of parameters for a new splice
• during requalification (each 2 years)

Process capability proof has to made according to AA 3091 / appendix 8

For the new splice respectively the smallest and the biggest splice (at requalification, wear
part exchange)

Coverage:
• cmk-calculation from 50 x peel force / tensile strength tests
• 1 x bending test
• 100% visual inspection
• 1 micrographics including determination of compression ratio

The detected results are valid for all machines at this plant of the same type and with the
same options.

The results are documented and released by QM.

Result

The machine (splice parameter) capability index : cm, cmk ≥ 1,67.

Just for peel test with critical splices, capability index cm, cmk >1,00, if all values in a save
range, at least 20% over the minimal required values.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 42

Welded Splice Evaluations and Approvals –
Capability Approval of Splice Parameters – Small Evaluation

Execution

Schedule :
• after modification of splice parameters
• after exchange of wear parts (anvil / sonotrode)

Coverage :
• 5 x peel force / tensile strength tests
• 1 x bending test
• 100% visual inspection
• running cpk-evaluation for ??? splices

The results are documented on the PDEK-Chart.

Result

The machine (splice parameter) capability index : cp, cpk ≥ 1,67.

PPE HQ Kitzingen / Training documentation Ultrasonic welding 43

Ultrasonic Welding Equipment –
LEONI – Standard Equipment

Ultrasonic
welding
equipment

PPE HQ Kitzingen / Training documentation Ultrasonic welding

Ultrasonic Welding Equipment –
LEONI – Standard Equipment: Schunk DS-20

Application: contacts
Materials: non-ferrous metals
Splice cross section [mm²]: 0,5 - 30
Frequency [kHz]: 20
Amplitude / Booster: 1:1 – 1:2,5
Weight [kg]: 13,5
Compressed air pressure [bar]: 6 (max. 10)
Compressed air use [m³/h]: 54
Noise level [dB(A)]: <70
Process time [s]: 0,1 – 1,0
Cut-Module: Optional
Insertion Aid: Standard (Leoni)

PPE HQ Kitzingen / Training documentation Ultrasonic welding 45

Ultrasonic Welding Equipment –
LEONI – Standard Equipment: Schunk Minic II Automatic PC 30mm²

Application: butt splices

inline splices
Materials: non-ferrous metals
Splice cross section [mm²]: 0,5 - 30
Frequency [kHz]: 20
Amplitude / Booster: 1:1 – 1:2,5
Weight [kg]: 13,5
Compressed air pressure [bar]: 6 (max. 10)
Compressed air use [m³/h]: 54
Noise level [dB(A)]: <70
Process time [s]: 0,1 – 1,0
Cut-Module: Optional
Insertion Aid: Standard (Leoni)

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Ultrasonic Welding Equipment –
LEONI – Standard Equipment: Schunk Global Splicer 40mm²

Application: butt splices

inline splices
Materials: non-ferrous metals
Splice cross section [mm²]: 0,5 - 40
Frequency [kHz]: 20
Amplitude / Booster: 1:1 – 1:2,5
Weight [kg]: 16,5
Compressed air pressure [bar]: 6 (max. 10)
Compressed air use [m³/h]: 54
Noise level [dB(A)]: <70
Process time [s]: 0,1 – 2,0
Cut-Module: Optional
Insertion Aid: Standard (Leoni)
GT – Ground Terminal: Optional

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Ultrasonic Welding Equipment –
LEONI – Standard Equipment: Telsonic TelsoSplice 40 mm2

Application: butt splices

inline splices
contacts
Materials: non-ferrous metals
Splice cross section [mm²]: 0,5 - 40
Frequency [kHz]: 20
Amplitude / Booster: 1:1 – 1:2,5
Weight [kg]: 12
Compressed air pressure [bar]: 6 (max. 10)
Compressed air use [m³/h]: 54
Noise level [dB(A)]: <70
Process time[s]: 0,1 – 1,5
Cut-Modul: Not available
Insertion Aid : Not available

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Schweißanlagen –
LEONI – Legacy Equipment

The following legacy equipment is possibly still in use. It does no longer meet
current requirements and can not be retrofitted to these.

STAPLA – Alpha 20, Octopus, Moskito

AMTECH – 2032, XL

SCHUNK – RK2000

This ultrasonic welding systems may no longer be obtained!

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Ultrasonic Welding Equipment –
Technical Details: Computer

The computer (PC) allows using a Windows software easy operation of the welding
system.
On the computer the different splices are created, stored and their parameters defined.
The defined splices can be used to form welding sequences which can be processed
later. The welding parameters can be easily changed and adapted.
The selection of the splices and sequences to be welded can be made by the operator by
means of a keyboard, mouse or barcode readers or is given ​​by
​​ a host computer.
During the welding process by the computer for each node are automatically provided
the welding parameters and transmitted to the controller. The computer monitors the
quality of the weld during the process. The welding results are displayed on screen and
collected in a statistics file. These results can be viewed at any time over a selectable
period.
Also several ultrasonic welding systems may controlled from a host computer system
(networked control).

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Ultrasonic Welding Equipment –
Technical Details: Tasks of Control Software

Operation of equipment Statistics

selection of splice
counter

selection of welding operation (single
statistic, failure statistic
splice, splice sequence)
log file

save of defined splices
storage of all welding results

batch selection, also by barcode scanner

Provision of welding parameters Visualisation

energy
design of splice (cables, cross section)

welding pressure
splice height before welding - H1

amplitude
splice height after welding - H2

width
energy usage

welding time

tolerance limits

failure messages

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Ultrasonic Welding Equipment –
Technical Details: Generator

The generator converts electrical energy from the electricity network (400 V / 50/60 Hz)
into a high-frequency high voltage (e.g. 1400 V / 20 kHz). Other common frequencies are
35 kHz, 40 kHz or 70 kHz.
For the ultrasonic metal welding has to be ensured a high constancy of the amplitude of
the tool to ensure a good welding quality. Furthermore, the frequency of electrical
vibrations, which are supplied from the generator must always exactly correspond to
the resonant frequency of the oscillator system.
To compensate for interferences in the operation such as temperature increase, welding
pressure fluctuations, etc., the generator has an amplitude control, which makes the
amplitude for the entire process time constant at the sonotrode. In addition the
generator has a frequency control, which adjusts the generator frequency according to
the resonance frequency of the oscillator system. On the generator, the desired value of
the amplitude of the oscillator system can be adjusted between 50% and 100% of the
maximum amplitude.
The maximum power output of generators is limited by the piezo elements of the
converter. Usual values are depending on the application 3000 - 5000 watts.

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Ultrasonic Welding Equipment –
Technical Details: Vibration System

The vibration system consist of

converter

booster

sonotrode

The vibrations of the converter stimulate using the booster the sonotrode to vibrate.

converter

booster

sonotrode

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Ultrasonic Welding Equipment –
Technical Details: Converter

The converter transforms the electrical oscillation into mechanical vibrations. For
conversion are used today especially electro-mechanical methods:

piezoelectric sound transducers

magnetostrictive sound transducers
Mainly are used piezoelectric converters.

Piezoelectric effect Inverse piezoelectric effect (used in converter)

Generating an electrical voltage when Generating a mechanical movement when
exposed to mechanical force exposed to an electrical voltage
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Ultrasonic Welding Equipment –
Technical Details: Booster

The booster can be used to increase or decrease the amplitude of the mechanical
vibration, but is not mandatory. Simultaneously, the booster is also used for the bearing
of the oscillator system in the machine.
Typical translation ratios of the booster are 1:1 or 1:1.1 in splice welding machines and
1:2 in terminal welding equipment.

converter booster sonotrode with transformation

booster

working
amplitude
start
amplitude
bearing ring

Transformation B:A = 2:1

Principle of amplitude amplification with 2:1-booster

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Ultrasonic Welding Equipment –
Technical Details: Sonotrode

The sonotrode is the actual tool of the ultrasonic welding machine. Depending on the
geometric design of the parts to be welded, there are a variety of different sonotrodes
that differ primarily in the design of the work surface. The counterpart to the sonotrode,
the anvil, is also profiled, but does not move.

work surface

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Ultrasonic Welding Equipment –
Technical Details: Structure of Sonotrode / Anvil (1)

EK profile NC riffle profile

Properties Properties

structured sonotrode and anvil
structured sonotrode and anvil

structures distributed evenly
structured side groves

structure in centre of anvil higher than
structure in centre of anvil higher than
surrounding structures surrounding structures

structures does not cover beginning and
structures cover all areas of the working
end of the working area area
Principle Principle

anvil
Anvil
A
A
lateral lateral
guide guide

sonotrode
sonotrode
A-A: A A-A:
A

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Ultrasonic Welding Equipment –
Technical Details: Structure of Sonotrode / Anvil (2)

EK profile NC riffle profile

Advantages and disadvantages Advantages and disadvantages

Advantages for small total cross-sections
Advantages for bigger total cross-sections

Outer teeth have large distance from the
Teeth go up close to the edge of the tool,
tool end, that’s why the splice will not thereby improving the 1 mm - strand
always be completely welded to the - protrusion problem (brushes at the strand
there may be sticking out strand ends. ends)

At lateral boundaries (horizontal anvil and
side shift) exist light profiles. This avoids
the formation of loops and movements of
the strands to the side

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Ultrasonic Welding Equipment –
Technical Details: Structure of Sonotrode / Anvil (3)

EK profile NC riffle profile

welded splice from anvil side welded splice from anvil side

The anvil is raised on the middle tooth

slightly, thus there arises the greatest
compression and a kind of breaking point
for the peeling test

welded splice from sonotrode side welded splice from sonotrode side

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Ultrasonic Welding Equipment –
Requirements to the Welding Equipment

The welding equipment is to be used and to monitor in accordance with the instructions
of the tool manufacturer's.

The welding equipment must be able to produce reliable splices during his lifetime.

The welding machine must be equipped with correct tools and wear parts required for
the processing of the planned material.

Equipment is also assessed by testing of welded splices produced with the tool to be
evaluated (tensile strength, peel forces, welding surface structure)

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Ultrasonic Welding Equipment –
Maintenance (1)

After all maintenance actions:

test with calibration pin the correct closing dimension (width) according to the
manufacturer's specifications

comparison of the dimensions of the welded splice with the displayed dimensions (width,
height)

After each exchange of wear parts (sonotrode and anvil):

test of two smallest and biggest splices 5 x peel force / tensile strenght, 1 x bending test

documentation of the values in the PDEK

Daily:

cleaning of the anvil and sonotrode

Weekly:

control condition and wear of the tool surfaces very carefully

control the correct closing dimension

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Ultrasonic Welding Equipment –
Maintenance (2)

Use original spare and wear parts only

The adjustment, repair and maintenance work has to made according to the
manufacture’s operating instruction and the LEONI maintanance plans.

WP 3120 WP 3069 WP 3026

Schunk GS Schunk Minic Stapla Twin/Moskito

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Standards and Specifications –
Customer Specifications

Customer Specification

VW-Group cross section ratio (smallest : largest cable) in a splice max 1:4
VW 60307 max. quantity of cables for butt splices: 15; inline splices: 5 + 5
tolerance at height detection before welding: 5% - 7%
micrographs: all strands deformed, compression degree 85 –
95%
BMW-Group cross section ratio (smallest : largest cable) in a splice max 1:3
GS 95006-3 max. quantity of cables for butt splices: 15; inline splices: 5 + 5
(only in case of exceptions)
tolerances: faults must be detected reliably, material tolerances
should not have generate fault messages
micrographs: the single strand must still visible, no massive
splice, compression degree 85 – 95%

GM-Group same criteria as for crimping

GMI 12590 micrographs: compression degree <100%
CV - DAF Standard Without specific targets, only visual criteria
PS 1673467
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Standards and Specifications –
LEONI Internal Specifications

VA 3049 - Release of AA 3006 – PA 3005 –

production processes Procedure for Rework Machine – and Process
and equipment Capability proof PDEK

VA 3021 Enclosure 3 – AA 3029 – PA 3030 –

Released Test Process Control Chart – Tolerances for Cutting
Equipment PDEK and Production

AA 3044 – PA 3042 –
Determination of the Cutting, Dismantling,
Wire Cross-Section and Stripping of Wires

PA 3072 –
AA 3092 –
Ultrasonic Welding (USS) Firm Cable Joints
(Cable Splice)
- Splices

AA 3122 - Test specifi-

cations for releasing and
commissioning of
production equipment

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Standards and Specifications –
Work Instruction AA 3092 (1)

In the work instruction AA 3092 are all ultrasonic-related issues defined.

Issue Content of LEONI work instruction

Equipment - Machine specific file
- Permission setting (teach mode, operation)
- Maintenance
- Re-qualifizierung of equipment
- Definition of capability approvals for splices
Prozess flow - Definition of process monitoring and tolerances
- Usage of options (ASSK)
- Notes for subsequent isolation
- Dealing with n.i.O. welds
- Dealing with rework
Product - Approach for parameter identification and splice evaluation
properties - Splices geometry and structure
- Cable requirements (max. storage time, LV112, allowed cable
types)

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Standards and Specifications –
Work Instruction AA 3092 (2)

Issue Content of LEONI work instruction

Test - Directive on visual inspection
- Test methodology (bending-, peel-, tensile strength test)
- Calculation of compression degree
- Tolerances (forces, dimensioning, ...)
- Quality documentation

Further - Pass / fail examples

Explanations - values ​​for
​​ peel and tensile strength tests
- Description of inspections during production
- Control limits for tensile strenght and pull forces at production start (later
determined from PDEK card)
- Chart of allowed cable combinations

Handling - Requirements on operator

- Requirements for cleanliness and handling
- Cable placement guidance
- Technical aids for asymmetric placement

Development - Design rules

Production - Parameter optimisation for symmetric splices

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Final Test –
Section 1: Operator, Technical Service, Process Owner

xxx

PPE HQ Kitzingen / Training documentation Ultrasonic welding 67

Final Test –
Section 2: Technical Service, Process Owner

xxx

PPE HQ Kitzingen / Training documentation Ultrasonic welding 68

Final Test –
Section 2: Process Owner

xxx

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