Ultrasonic metal welding

for wire harness

About us Wire Harness

ultra fast. ultra strong. ultrasonic.

Our 300 employees worldwide develop and produce innovative ultrasonic welding machines - and,
together with our representatives, are always close to our customers. In addition to our headquar-
Ultrasonic welding in the wire harness industry
ters in Wettenberg (Germany), we have locations in Graevenwiesbach (Germany), Boston (USA), Mo-
Ultrasonic metal welding is one of the most important joining
scow (Russia), Kenitra (Morocco) and Taicang (Jiangsu Province, China). We also have a global sales
technologies employed in the manufacture of wire harnesses
and service network.
for the automotive, construction equipment and household
appliance industries. Among other things, the process is
used for joining multiple wires with each other as well as
for joining wires with grounding terminals or high-current con-
tacts. The wire cross-section sizes which can be ultrasonically
welded ranges from 0.08 square millimeters to 200 square
millimeters. Compared with crimping or resistance welding, ul-
trasonic welding offers numerous advantages. These include
Power Electronics Battery Cooling Technology Service Innovations the excellent electrical properties of the joint, extremely low
energy consumption and comprehensive process control and
¬ IGBT Modules ¬ Battery modu- ¬ Copper tubes ¬ Technical advi- ¬ Cutting corresponding process data management.

¬ IPM Modules les for refrigeration ce and support ¬ Punching

¬ Cell contacting ¬ Li-Ion Techno- circuits ¬ Process de- ¬ Welding of plas-
Systems logy ¬ Capillary tubes velopment and tics and textiles
¬ Signal Termi- ¬ Capacitors for thermostats integration ¬ Cut & Seal by
nals to subst- ¬ Anode/cathode ¬ EX-certified ¬ Software combined pro-
rates connections development cedure
¬ Copper/Tab con- ¬ Training system
nections
Wire - Wire Wire - Wire

Minic-III
The Minic-III is the most modern, fas-
test as well as most user-friendly and
low-maintenance ultrasonic welding
machine on the world market today. A
benchmark for the worldwide leading wi-
re-harness manufacturers, this machine
has delivered the best welding results
with respect to strength, Cmk / Cpk as
well as the visual appearance of the
splices produced, in all applications.
M-Splice
¬ Cross section range: 10 mm² to 60 mm²
¬ Integrated camera for checking the insertion position as well as image recognition of the wel-
ding result
¬ Plug & Play: Modules and control elements are interchangeable
¬ Integriertes elektrisches Thermomanagementsystem
¬ Movable end stop, which can be defined for each splice
¬ Insertion aids: Anti Side Splice Kit (ASSK), Laser Positioning System
¬ Cutting up to 60 mm² possible
available from the second half of 2020

¬ Cross section range: 0,26 mm² to 30 mm²

¬ Suitable for aluminium, copper and mixed connections (cascade)
¬ Plug & Play functionality through integrated ID chip
¬ Sequence welding possible
¬ Easily accessible maintenance and cleaning
¬ Compressed air-free cooling system

i
Numerous insertion aids are available for the Minic-III: Cable fit-in (CFI), wel-
ding area illumination, laser positioning system, pick by light. Please do not
hesitate to contact us.

Variation X-Splice Minic-Twist L-Splice

¬ Suitable for welding X- and Y-splices
¬ Also available as retrofit kit
¬ All other applications of the Minic-III can also
be welded with this variant
¬ Specially designed for the welding of twis-
ted wires
¬ Thanks to the insertion aid, twisted wires
can be welded easily and with optimum
results
¬ Cross section range: 20 mm² to 100 mm² ( variation 100) resp.
20 mm² to 200 mm² ( variation 200)
¬ Suitable for aluminium, copper and mixed connections (cascade)
¬ Withstands highest thermal and mechanical loads
¬ Designed for manual operation as well as for integration into fully automatic production systems
¬ Two design variants are available for optimum, ergonomic operation
¬ Wire fixation for manual insertion of wires
¬ Insertion aid optionally available
Wire - Terminal Wire - Terminal

DS20-III
¬ Cross section range: 1.5 mm² to 35 mm² (copper) or 2.5 mm² to 42 mm² (aluminium);
Terminal welding
optional: 50 mm² copper cables, 60 mm² aluminium cables
¬ Automatic terminal feeding is available in 0°, 90° and 180° versions
In addition to wire to wire connections, ultrasonic welding is
ideally suited for the welding of wires on terminals. Different
¬ Quick and easy tool change
material combinations as well as terminal geometries can
be welded. The result is a connection with extremely high
strength and outstanding electrical properties.

With the DS20-III all common terminals in alu-

minium and copper can be welded. Thanks to an
innovative hood concept, the machine is 360°
accessible and therefore very easy to maintain.

DS20-GT
¬ Cross section range: 1.5 mm² to 25 mm²
¬ With insulation crimp
¬ Applications in the field of ground terminals
Wire - Terminal Wire - Terminal

DS20-II HECTA
¬ Cross section range: 6 mm² to 120 mm²
¬ Copper, aluminium and mixed connections are possible

at i o ns
c
appli
New i e s
i l i t
po ssib
N ew
e
V o ltag
The DS20-II represents a milestone in wire harness produc- High ilty
b of
tion: This machine makes it possible for the first time to weld E - M o ex S h a p e
l
wires in this cross-sectional area to terminals. Comp als
in
Term der
The wires can be connected to different contact parts with a un
precision that is unique in this application area.
A l l ro

ju i c e
o re stem

#m
r Sy
h Powe
Hi g
tive
LS-C t h ro ugh
in nova

¬ Cross section range: 6mm² to 200mm²

suitable for numerous terminal applications, such as tubu-
lar cable lugs or bus bars
¬ Welding of copper and aluminium wires to terminals
¬ With insulation crimp and cutting device
¬ Integration into automated production lines possible
¬ Optimum accessibility of the welding area
Technical data Technical data

Technical data
Splicing machines
Minic-III M-Splice L-Splice
20 - 100 mm² or
Cross-sectional area 0,26 - 30 mm² 10 - 60 mm²
20 - 200 mm²

Generator power 3 kW 6 kW 6 kW / 9 kW

Frequency 20 kHz 20 kHz 20 kHz

3 x 400 V, N, PE or
Power supply 3 x 400 V 3 x 400 V, N, PE
3 x 200 V / 220 V, PE

Compressed air 6 bar 6,5 bar 6,5 bar

i
ca. 470 x 185 x 205 ca. 466 x 433 x 593 ca. 472 x 441 x 817
Dimensions (mm) Different versions and options are available for all machines. These include
(H x W x D) (H x W x D) (H x W x D)
ca. 13 kg (incl. cutting and table variants, insertion aids, touch screens and barcode scanners.
Weight (kg) ca. 35 kg ca. 320 kg
Just contact us!
pneumatic system)

Terminal machines
DS20-II DS20-GT DS20-III LS-C

bis 35 mm² (Cu),

Cross-sectional area 6 - 120 mm² 1,5 - 25 mm² 6 - 200 mm²
bis 42 mm² (Al)

Generator power 4 kW / 6 kW/ 9 kW 3 kW 4 kW 4 kW / 6 kW / 9 kW / 13,5 kW

Frequency 20 kHz 20 kHz 20 kHz 20 kHz

3 x 400 V, N, PE (4 / 6 / 9 kW) 3 x 400 V, N, PE 3 x 400 V, N, PE 3 x 400 V, N, PE (4 / 6 / 9/ 13,5

or kW) or
Power supply or or
3 x 200 V, PE (4 kW) 3 x 200 V, PE 3 x 220 V, PE (4 kW) 3 x 200 V / 3 x 220 V, PE (4 kW)

Compressed air 6,5 bar 6,5 bar 6,5 bar 6,5 bar

1045 x 565 x 400 476 x 346 x 610 730 x 790 x 830 1350 x 520 x530
Dimensions (mm)
(H x W x D) (H x W x D) (H x W x D) (H x W x D)

Weight (kg) ca. 600 kg ca. 150 kg ca. 300 kg ca. 900 kg
 200/11-2019 Subject to technical changes and errors excepted. Illustrations similar.
Follow us on LinkedIn:
http://www.linkedin.com/showcase/schunk-sonosystems/

Schunk Sonosystems GmbH +49 641 803 0

Hauptstrasse 95
sonosystems@schunk-group.com
35435 Wettenberg
Germany www.schunk-sonosystems.com