Compact copper

operate flexibly, even at bottlenecks

In increasingly small spaces, technical products combine an increasing number of electrical connections. Established solutions for cable technology such as soldering or crimping often reach their technical limits in such a situation. High process costs and space requirements for the connections are to blame. The requirements increase with applications with high wire cross-sections. With high currents comes the need for especially reliable connections. That’s why specialists are needed: With fully automatic ultrasonic compression, we offer a high-performance alternative to traditional processes in cable manufacturing.

Ultrasonic compression opens new possibilities

Soldered or crimped cables used to be good enough for the production of electric connections. However, there are increasingly more applications that clearly benefit from a break with traditional solder, sockets, and outlets. With ultrasonic compression, several cords can be connected during assembly with additional material and shorter process times. At the same time, the connection junction can be customized.

After skinning, the connections are set with low pressure for further processing. The machine then stimulates individual cords with high-frequency oscillation. This causes the material to rub against itself at a high velocity. The distance between the wires is less than a nanometre – so small, that the surfaces exchange electrons. This quickly creates an all-metallic and long-term stable bond. No mixed parts are added that could influence the electric qualities of the braided material. Because the material is not subjected to high temperatures during compression, there is no thermally-caused changes in the material qualities.

Applications for ultrasonic compression

Save space and costs

Applications with special requirements regarding space constraints, as well as quality and durability in the electric connection, benefit the most from this process. The deciding advantage of ultrasonic compression is the lack of fasteners. This allows for low contact resistance, in addition to space and cost savings.

A connection without an end sleeve requires less space in the same wire cross-section. This, in turn, is especially helpful with contacts in small spaces. An additional, technically valuable benefit: There is no additional material that could influence the connection quality. The process is also especially flexible. The design of the compression area is customisable to exact requirements, such as the length of the cable to be compressed. The process can also be easily surveilled – an essential condition to guarantee stable production quality. Ultrasonic compression also offers additional possibilities, as it reliably welds not only copper cables, but also other materials.

Are you interested?

We are happy to inform you personally about ultrasonic compression

Ralph Schmid

Cable assembly from one provider

toward tool-free assembly

We compress cables with cross-sections of up to 25 mm² fully automated. Those are dimensions often used in especially challenging applications, such as in high performance electronics in electric cars. We can integrate ultrasonic compression seamlessly into the digital processes of wire assembly. After cutting the individual braids to length, the ultrasonic compression begins on an automatic terminal. We then deliver the printed cables to you in the correct order – ready to be assembled tool-free.