Laser Welder LW2095 – Fully automatic Laser Welding System with two weldheads and an extra large working area

Smart Welder - Ultrasonic Welding Machine with large, fully accessible working area – for terminals, pins, copper rivets and sleeves

Smart Welder combine the best of two technologies:

• The force and ultrasonic power of ultrasonic welding equipment
  and
• The flexibility, precision, speed and advanced process control features of wire bonding machines.

Smart Welding is the leading-edge technology in producing ultrasonically welded connections. This is due to increased process control, driving the limits of connecting different material combinations (e.g. for applications like power electronics and battery packs).
Smart Welders by Hesse, can precisely position a sonotrode to a product. An image recognition system determines the exact weld location very quickly and accurately, based on a derivation of an optimal trajectory. Together with long and narrow sonotrodes, this allows small pitching and compact products/higher power density.
Further advanced functions include touchdown sensing, precise and dynamic contact force control, diverse process control features such as monitoring of ultrasonic characteristics and deformation (ref. DVS 2811), and standardized interfaces for assembly line integration.
Smart Welders can, like ultrasonic wire bonders, flexibly handle a large variety of products. New products only require a program change and possibly adapted clamping and automation.

Fully automatic Laser Welding System with a large working area

The Laser Welder LW1089 is a laser welding system for fully and semi-automatic deep penetration welding of aluminum and copper leads on DCB substrates, in power electronics, battery cells and modules, or other electronics manufacturing components. Laser welding uses a laser beam to create intermetallic joints along a weld seam.

Both temporal and spatial laser power modulation enable different weld geometries and depths with the Laser Welder LW1089. A movable holding-down device avoids contamination of the surrounding area by weld pool ejections („splashes“) during the welding process.

Constant precision throughout the manufacturing process is ensured by high axis accuracy and a professional process control, which ensures reproducibility of clamping force („zero-gap-challenge“) and welding conditions. This standardized „clamp and weld“ concept offers fast adjustment to different product variants and flexible product changeover. It also makes it possible to react automatically to component tolerances of the joining partners to be welded.

Features & Process Advantages

• Large working area: 410 mm × 480 mm × 75* mm (X×Y×Z)
• Fast weldng times
• Different weld geometries and depths due to temporal and spatial laser power modulation
• Active vertical axis with sensor technology
• Sensor for touchdown detection in combination with an adjustable hold-down force avoids damage to sensitive contact partners
• 1.5 kW laser beam source
• Image recognition (PR) for precise detection and correction of the weld location
• Minimal mechanical and thermal load
• Process monitoring via sensors for process illumination (plasma, thermal illumination and backscattered radiation)
• Standardized interfaces for line integration

Application examples:

• Welding of Cu leads on DCB/AMB
• Welding of Cu leads on Cu Busbar
• Welding of battery cells
• Welding of Al leads on Al