TECH-SONIC, Inc. products

USCAR-45 defines test methods and performance requirements for ultrasonically welded wire-to-wire splicing for automotive applications. The tests defined in this specification subject samples on tests to stresses that simulate a lifetime of exposure for a road vehicle. Stresses include Thermal shock, Temperature and Humidity cycling, and Mechanical Abuse. With the growing market of Electric Vehicles, quality control for wire splicing is becoming more important to ensure the functionality of the electrical components in Electric Vehicles EV. In compliance with USCAR-45, the 3620WS2P ultrasonic wire splicing machine has the ability to detect 3% of missing strands of total cross section area.

TECH-SONIC’s patent-pending closed-loop control wire to ring termination welder, model US-3620SRT, provides a whole new ultrasonic metal welding capability beyond conventional ultrasonic metal welds. This particular wire termination welder is capable of welding multiple wires to ring terminals with ease and very little stress when bonding materials. It produces single-point ground terminals and it can accommodate a variety of terminals without changing terminal nest hardware.

Conduction is a growing concern for many EV manufacturers in today’s competitive landscape. In order for EV’s to function properly, effective low resistance wire bonding is required. Ultrasonic welding is the ideal joining process for joining wires, efficiently producing low-resistance bonds. TECH-SONIC’s patent-pending closed-loop control ultrasonic wiring termination machine, model US-3620MAK-S, provides a new ultrasonic metal welding capability beyond conventional ultrasonic metal welders. It bonds single point ground terminals and can accommodate a variety of terminals by changing terminal nest hardware. It uses a microprocessor-controlled ultrasonic welder and servo-controlled spot welding hardware that can weld multiple wires onto a single terminal and provide a stress-free joint. In compliance with USCAR-38, it has the ability to detect 3% of total CSA.

Ultrasonic metal welding is a crucial joining technology used in the creation of wire harnesses for many industries, but primarily automotive. The process involves joining multiple wires with each other or joining wires with terminals or conductive contacts. Compared with more traditional welding methods like crimping or resistance welding, ultrasonic welding offers several advantages. These include the higher quality of weld joints, better process control and low energy consumption. The US-3620WN2 ultrasonic wire splicer creates the highest quality welds; a strong, surface molecular, solid-state bond that is clean and has high electrical conductivity.

The TECH-SONIC explosion proof ultrasonic tube sealer, model 3620TS-EX is used primarily in applications that pertain to refrigerator manufacturers and HVAC manufacturers. The Ultrasonic welding process replaces traditional brazing methods that are incompatible with flammable gas. The US-3620TS-EX ultrasonic tube sealer is used to seal charged copper tubes in accordance with the Kigali agreement (by law). The US-3620TS-EX is Explosion-Proof Certified for operation with flammable HC alternatives, creating a spectacular solution for the phaseout of Ozone- Depleting Substances (ODS). These certifications include Ex-Zone 2, Class 1, and Division 2 Certification.