Applications include tab welding on cylindrical cells, foils and tab welding on prismatic cells, and battery management modules such as sensing harnesses which use foils or flat cables. Telsonic''s TSP range are supplied as standalone machines, or modules for integration into automated systems for the production of battery cells and
In fact, torsional welding is sometimes found to be the only solution for electric car battery manufacturers and in the termination of high-voltage cables. Other examples where torsional ultrasonic welding proves to be the superior method are bus bars, 3D terminals and integrated gate bipolar transistors (IGBT).
With the Telsonic PowerWheel, torsional welding provides such gentle vibrations that studies show the effect is much less for both stranded cables and flexible busbars, depending on the terminal designs (see figure 9). This allows shorter cables and appropriate connectors be welded together.
Ultrasonic welding technology is a proven joining process that is increasingly specified by carmakers for use in EV for cables to terminal connections, busbars, battery manufacturing and power electronics. Linear welding is the more traditional and well-known technique used by all equipment manufacturers as a standard process for splicing wires.
The larger conductor / termination sizes and cross sections involved in EV applications require high power ultrasonic oscillations using Telsonic’s Torsional technology to deliver high levels of energy within very short process times to produce the weld.
Torsional energy is gently exerted on the area of the joint, thus suitable even for highly sensitive parts. On the other hand, even very strong forces may be applied in a very short time, which is critical, for example, for joining aluminum or copper foils.
However, like many other joining processes, linear welding comes with limitations in size, difficulties welding in smaller areas and certain geometrical shapes, problems with orientation of welding, and vibration effects on peripheral components.
Applications include tab welding on cylindrical cells, foils and tab welding on prismatic cells, and battery management modules such as sensing harnesses which use foils or flat cables. Telsonic''s TSP range are supplied as standalone machines, or modules for integration into automated systems for the production of battery cells and
Applications include tab welding on cylindrical cells, foils and tab welding on prismatic cells, and battery management modules such as sensing harnesses which use foils or flat cables. …
The Telsonic innovative torsional welding technique has created breakthrough applications that were impossible or unacceptable up to the last decade. Now, the technology is increasingly specified by carmakers for use in …
The Telsonic innovative Torsional welding technique has created breakthroughs applications that were impossible or not acceptable up to last decade. Now the technology is increasingly …
In the case of lithium-ion batteries, very thin films can be welded into film packages using Telsonic torsion welding, without damaging the delicate top film. With this method, individual films measuring 10–20 µm in thickness and made of aluminium or copper are reliably
Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell electrode foils and collector tabs to end caps.
torsional process over conventional ultrasonic welding is the "reach," plus the process is gentler on sensitive or delicate product assemblies. Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell
With its SONIQTWIST® torsional ultrasonic welding process, Telsonic has established a key technology that is revolutionizing the production of cylindrical battery cells and proving essential to meet the growing demand for high-performance batteries for electric vehicles.
Telsonic''s Soniqtwist torsional ultrasonic welding process provides ideal conditions for welding the poles of cylindrical battery cells. The process has already proven itself in many different industrial areas, and the systems can be easily and cost-effectively fully integrated into various production plants (Figure 1). Examples include round ...
In the case of lithium-ion batteries, very thin films can be welded into film packages using Telsonic torsion welding, without damaging the delicate top film. With this method, individual films …
In fact, the Torsional welding is sometimes found to be the only solution for electric car battery manufacturers and in the termination of high-voltage cables. Other examples where torsional ultrasonic welding proves to be the superior method are bus bars, 3D terminals and integrated gate bipolar transistors (IGBT). The torsional process is suitable for welding
Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell electrode foils and collector tabs to end caps. Conversely, the same technology can be used with higher force and power to weld round stud type ...
Torsional ultrasonic welding components Torsional resonator SE2010TC TR2.4 TR6.5 TR10 Peak power 1.2 kW 2.4 kW 6.5 kW 10 kW Frequency 20 kHz 19 kHz 20 kHz 20 kHz Converter cooling Yes Yes Yes Yes Generator type MAG-T020012 MAG-T019024 SG-22-6500 SG-22-10000 Press type TSP750 TSP8000 TSP3000 TSP torsional welding presses TSP750 TSP3000 TSP8000
Ultrasonic welding, particularly torsional welding technology, allows welding of larger size welds, gentle vibration, and ability to join harder to reach areas. These capabilities will allow further implementations of busbars outside the EV battery packs as the industry moves forward. Figure 5 provides a few examples of how ...
The application was completed using torsional, ultrasonic SONIQTWIST ® welding technology, which offers a number of advantages. Configuration advantages By creating a firm weld without any additional tools, ultrasonics generates corrosion-resistant electrical connections with low contact resistance at a level similar to that of the original materials.
battery cell "Jellyroll", where multiple welding sonotrodes can be integrated within a continuously rotating turret style system to achieve the throughput required.
Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell …
The Telsonic innovative Torsional welding technique has created breakthroughs applications that were impossible or not acceptable up to last decade. Now the technology is increasingly specified by carmakers for use in EV for weight control, battery packaging, cable to terminal connections, bus bars, battery manufacturing and power electronics.
Ultrasonic welding, particularly torsional welding technology, allows welding of larger size welds, gentle vibration, and ability to join harder to reach areas. These capabilities will allow further implementations of busbars …
Vertical Ultrasonic Torsional Welding for EV Applications Historically this ultrasonic process has been used for hard-to-reach applications at a range of different power settings, and for welding within recesses and welding onto ceramics (IGBT). The main reasons for and advantages of using the torsional process over conventional ultrasonic welding is the "reach," plus the process is ...
With its SONIQTWIST® torsional ultrasonic welding process, Telsonic has established a key technology that is revolutionizing the production of cylindrical battery cells and proving essential to meet the growing demand for …
The Telsonic innovative torsional welding technique has created breakthrough applications that were impossible or unacceptable up to the last decade. Now, the technology is increasingly specified by carmakers for use in EVs for weight control, battery packaging, cable to terminal connections, bus bars, battery manufacturing and power ...
Telsonic''s Soniqtwist torsional ultrasonic welding process provides ideal conditions for welding the poles of cylindrical battery cells. The process has already proven …
Figure 2. MA shapes of the torsional (13.7 kHz), operating (20.8 kHz) and bending (23.5 kHz) mode.E 3. Welding Experiments 3.1 Experimental set up A 1 kW ultrasonic generator (Sonic Systems L500/3-20) is used to drive the transducer and hence the welding horn, known together as the welding stack. A tensile test machine (Zwick Roell) is employed
Metal welding connections: point and circumferential welding geometry ; Low-vibration welding of electronic components ; Producing the peel-off function, e.g. aluminium covers ; Seal welding aluminium packaging without plastic coating; Telsonic''s torsional technique succeeds where conventional longitudinal ultrasonic technology reaches its ...
Low force / power torsional machines are ideal for foils, flat conductors, battery end cap tabs and delicate sensing components. Applications include collector tab welding on cylindrical cell electrode foils and collector …
metal spot welding, which uses torsional sonotrode vibra-tion to create a quasi-transverse vibration at the welding spot (type E in Figure 1). Typical ultrasonic metal spot welding machines provide ul- trasound powers of 0.5 to 10 kW at frequencies between 15 and 40 kHz, with the corresponding normal force reaching up to 10 kN. Contact areas of up to 100 mm² can be …
In fact, the Torsional welding is sometimes found to be the only solution for electric car battery manufacturers and in the termination of high-voltage cables. Other examples where torsional ultrasonic welding proves to be the superior method are bus bars, 3D terminals and integrated gate bipolar transistors (IGBT).
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