Enhanced Ultrasonic Metal Welding with Servo-Motor Driven Systems and Closed-Loop Control

Ultrasonic metal welding (UMW) is critical for battery foil joining, wire termination and electrical bus bar welding. This presentation compares servo-motor-driven and pneumatic-driven force delivery systems in UMW for these applications. A servo-motor system, coupled with a closed-loop quality control package, offers precise force and displacement control, enhancing weld consistency, tool life and minimizes weld defects. This contrasts with pneumatic systems, which are susceptible to variations in air pressure, leading to less precise force application and potentially lower and varying weld quality. Experimental results demonstrate that the servo-motor-driven UMW, with integrated quality control (Closed Loop Control Technology), achieves superior weld strength and uniformity compared to the pneumatic system. This improvement is attributed to the servomotor's ability to maintain a constant force profile and adapt to material variations through real-time feedback, this functionality, combined with AI will ultimately yield more reliable and robust ultrasonic metal welds.