Case
Shorter process times in ultrasonic metal welding
for battery manufacturing
In industrial battery production, foil stacks must be welded quickly, reliably and consistently. In this customized application, up to 80 layers of copper or aluminum foil are welded together. At one battery manufacturer, the existing welding process could not be accelerated any further without compromising stability. EUROSONIC analyzed the application with the aim of significantly reducing process time while ensuring stable and repeatable welding results.
The Challenge
Thin foils and large stacks of layers place high demands on the welding process. The joints must be mechanically robust and electrically reliable. With the existing ultrasonic system, stable operation was not possible at process times below five seconds. Further increasing the force or amplitude also failed to deliver the desired result.
According to the manufacturers’ specifications, both the previously used generator and converter had higher rated power outputs than the EUROSONIC components subsequently installed. However, the higher power ratings alone were not sufficient to reliably achieve the required process speed.
The Solution
EUROSONIC analyzed the existing welding process and selectively replaced the generator and converter. The sonotrode, anvil, application-specific material and fixture remained unchanged.
A EUROSONIC 5 kW ultrasonic generator and a EUROSONIC 6 kW converter were used. The components were integrated into the existing ultrasonic oscillation system and adapted to the application. This allowed the existing setup to be retained while operating the process with significantly shorter cycle times.
The Result: Approximately 70% Shorter Process Time
Following the upgrade, the process time was reduced from over five seconds to as little as 1.5 seconds. At the same time, more stable and repeatable process performance was achieved in the application described.
An efficient welding process depends on the interaction between the generator, ultrasonic oscillation system, application-specific material, anvil and process parameters. The rated power of an individual component alone does not adequately reflect this interaction.
Conclusion
What matters most is not the highest power rating, but the results achieved in production. In this application, EUROSONIC was able to significantly increase process speed and ensure stable operation. This case demonstrates the potential of the right ultrasonic technology, even within an existing system.
Targeted optimization of existing processes
When process times can no longer be reduced or a welding process becomes unstable at higher speeds, replacing the entire system is not necessarily required. EUROSONIC analyzes existing applications and evaluates which adjustments are appropriate for the specific process requirements.
Illustrative power and energy profile during ultrasonic battery welding: The time-based profile shows the controlled energy input during the welding process and the final release pulse within 1.5 seconds.
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