Hesse Mechatronics

Smart Welding –
The Smarter Technology

Smart Welding for Battery Packs of tomorrow

Smart Welding is the leading-edge technology in producing ultrasonically welded connections via ultrasonic metal welding (USMW/UMW). It is used in a variety of microelectronics applications, mostly for establishing electrical connections.

Smart Welding works at high speeds with precise process control and highest accuracies in ultrasonic metal welding. The ease of handling tolerances and the flexible design of the equipment make it beneficial for battery module and pack production. Smart Welders are available with different power levels and in different working areas. Ideal for battery packs,  Smart Welders can be used to weld connectors on cell and pack level such as (flexible) bus bars and tabs that connect battery management systems (BMS) and voltage sense contacts. A continuous quality and process monitoring enables all requirements of traceability according to semiconductor and automotive industry standards.

Smart Welder SW1089

Your Benefits

  • Up to 16mm² contact area for superior contact conductivity
  • Up to 1.5mm material thickness for superior current capability
  • Zero gap technology
  • Matching different materials (Hilumin & Al, Al & Al, Al & Cu, Ni & Al)
  • Pattern Recognition (PR) - to ensure best in class precision even on very large modules
  • Precise force control to avoid any cell damage
  • One weld traceability by unique Sonotrode code (machine readable)
  • Remote PR support (assist with your mobile device)
  • Best in class insitu process control (PiQC) to track your process data and get your quality alert during the welding process
  • Hesse designed Sonotrodes for your production
  • Hesse supports you from the first vision towards Start of Production (SOP)
    • Prototype welding
    • Consulting for weldable module design
    • Clamping and automation solutions
    • Qualification samples
    • Small volume production
    • SOP support
    • Full production support
    • Process optimization
    • Training for operators and up to your own trainer

Applications:

While some applications require ultrasonic power in the upper kW-range, in the packaging of semiconductor modules only relatively low ultrasonic power input is needed to weld its terminals. Such powers from 100W up to 1.5kW cover also smaller stranded wires or thin sheets of copper like used in battery cell contacting systems. To cover these applications smart ultrasonic welding was developed.

These applications below are found in many products of power electronics and battery powered motion, such as air mobility vehicles, forklifts, e-bikes, e-trucks and electric cars. The following section shows some example applications:

Power Semiconductor:

Terminals;
Copper Pins;
Leadframes

Battery Interconnection Systems:

Tabs of cell interconnection systems/battery cell contacting systems;
Current collectors/bus bars in battery interconnection systems;
Other electrical connectors for cell interconnection and voltage sensing

Advantages of ultrasonic welding with the Smart Welders of Hesse

  • Traceability of each weld

  • Highest grade of automation

  • Cost of ownership and foot-print optimized

  • No risk of electrical short due

  • Longitudinal vibration for a constant amplitude over the joining area

  • Low varying resistance of joint area due to stable intermetallics

  • Realtime quality monitoring by PiQC

  • No atmosphere and no melting temperatures are needed

  • Suitable to materials with high thermal conductivity

  • Oxide layers are compensated due to ultrasonic cleaning phases

  • Process programs can be handled centralized

  • Tolerances in the product (such as height, position, roughness, oxide layers etc.) can be compensated due to a real-time calculated and monitored welding process

  • Conversions to other product variants are characterized by low setup-up times and no changes on the machine