The ultrasonic metal welding process is often used for high-voltage cable termination and battery cable assembly. The variety of automotive terminal designs calls for a universal welding machine that can be adapted to many styles.

To address these requirements, Telsonic has introduced the MPX terminal welding machine, a universal welder with standardized modular options. Manufacturers can adapt the MPX to their wire-to-terminal connection requirements to cover a wide spectrum of design and manufacturing processes. In its simplest form, the MPX is a benchtop welding machine for spot-welding of battery applications. By adding standardized modules for specific requirements, the MPX can perform more complex processing tasks, such as semi-automatic termination. Once the terminal designs are defined, the MPX can be configured with all standardized and optional modules. 

Telsonic says the MPX universal welding machine offers these advantages:

• minimizing the changeover for similar terminals or different size cables for the same terminal
• easy integration of modular subassemblies when terminals require additional steps such as insulation crimping or automatic feeding of the terminals

The MPX allows the manufacturer to use the same machine for many different terminals. For high-volume production, the machine’s main platform is common for all applications, and facilitates customer training for operation, quality control and maintenance. The machine also enables application development at a customers’ site or at Telsonic’s application laboratory. Specific configurations of the MPX are defined by the terminal design (flat, 3D, with side walls) and process requirements such as:

• terminals with insulation crimp
• terminals require automatic feeding
• bad weld cutting device

Source: Telsonic