Sonobond Ultrasonics’ Dual Head SpliceRite continues to be the industry leader for ultrasonic splicing of wire harness assemblies. According to Sonobond’s vice president, Melissa Alleman, the Dual Head SpliceRite ultrasonic wire splicer is unequalled in its handling of large wire bundles.

She says: “This ultrasonic wire splicer is the latest in our SpliceRite series. It can reliably weld stranded copper wire bundles having cross-sections of 48 to 100 sq mm. It even accommodates lightly tinned or oxidised wires up to 60 sq mm without pre-cleaning. No other ultrasonic metal welder can accomplish these splices in a single pulse. All this makes the Dual Head SpliceRite ideal for fast, dependable, cost-efficient ultrasonic splicing of the heavy-duty cables used in wire harnesses for cars, trucks, trains, industrial machinery, and similar applications.

“Sonobond is looking forward to exhibiting the Dual Head SpliceRite at the 2012 National Electrical Wire Processing Expo in Milwaukee this May. Expo attendees are invited to come to Booth No 1540 to see this equipment in operation and inspect sample welds. Once they witness a demonstration of the machine’s wire splicing capabilities, they’ll understand why the Dual Head SpliceRite is the ultrasonic metal welder of choice for so many wire harness assemblers.”

Ultrasonic metal welding is now a well-accepted and frequently used method of assembling wire harnesses. It creates solid-state metallurgical bonds with high conductivity. This is accomplished without the need for filler metal materials and without clipping, soldering, crimping, or dipping. The process does not produce arcs, sparks, or fumes and does not result in melting of the weldment.

However, the Sonobond Dual Head SpliceRite is considered truly unique among ultrasonic wire splicers. It consists of two ultrasonic transducers and couplers-one above and one below the weld area-plus a set of pneumatically driven jaws. These jaws gather the wires tightly to a preset width. The upper tip then descends to complete the compressing of the bundle and ultrasonic power is applied. When the cycle ends, the jaws open so the wires can be removed. A support for the wire array can also be integrated into the tooling system if necessary. This cost-effective process produces no waste, consumes only minimal energy, and is environmentally-friendly.

PATENTED SYSTEM

All Sonobond metal spot welders, including the Dual Head SpliceRite, are made in the US and use the unique, patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is utilised while the line of force is directly over the parts to be welded. This creates precise, dependable welds without bending stress or stalling. It also permits splicing of most oxidised and tinned metals with just one pulse and without pre-cleaning. No other ultrasonic metal welding system can weld oxidised or tinned surfaces.

Sonobond’s Dual Head SpliceRite features heat-treated, tool steel taper lock tips that can last for 100,000 welds or more. These are designed for quick tooling changes and fool-proof placement. The equipment has a 3500-watt power supply with a microprocessor that stores and recalls up to 250 jobs.

Welds can be controlled by height, by energy, or by time. The entire process is completed in one quick step without melting the material. Like Sonobond’s other ultrasonic welders and bonders, the Dual Head SpliceRite can be operated easily and requires only a minimal amount of training.

In 1960, Sonobond, then known as Aeroprojects, received the first patent ever awarded for ultrasonic metal welding. Over the intervening 52 years, the company has continued to enjoy a well-earned reputation for innovative leadership and quality engineered products.