Sponsored by Telsonic.
Telsonic’s superior torsional SONIQTWIST® welding know-how has been efficiently utilized in a groundbreaking answer for fixing silver-plated aluminum busbars utilizing screws. This innovation, developed in collaboration with the KERN-LIEBERS Group, a producer of precision stamped elements, guarantees to set new requirements for reliability and conductivity in electrical connections for industrial functions.
The Problem: Securing Silver-Plated Aluminum Busbars
The KERN-LIEBERS Group has pioneered a way to coat aluminum busbars inline with silver. This silver coating enhances the busbars’ conductivity however poses a problem for safe attachment utilizing screws, because of the rest properties of aluminum. The answer requires the combination of a copper sleeve into the busbar, offering a sturdy and electrically conductive connection that enables for screw fixation.
The Resolution: Integrating Copper Sleeves with Ultrasonic Welding
To implement this answer, a copper sleeve is positioned right into a pre-punched gap within the busbar. The sleeve is designed with an outsized collar to facilitate the transmission of torsional ultrasonic vibrations by a sonotrode. This course of welds the copper sleeve to the silver layer, guaranteeing the integrity of the silver coating is maintained.
Telsonic’s torsional SONIQTWIST® know-how – the torsional welding system TSP3000.
Configuration Benefits
The combination of silver coating expands the compatibility of ultrasonic welding to new aluminum alloys. Ultrasonic welding gives a process-secure and long-term secure connection between dissimilar metals with minimal electrical resistance. The manufacturing of busbars with punched holes is cost-efficient, and integrating the silver coating into the manufacturing course of eliminates extra transport prices for exterior coating.
Profitable Implementation: Torsional SONIQTWIST® Expertise
This software was efficiently executed utilizing Telsonic’s torsional SONIQTWIST® know-how. The torsional welding system TSP3000, depicted above, demonstrates Telsonic’s functionality to fulfill the demanding necessities of commercial functions, guaranteeing dependable and conductive connections.