ultra fast. ultra strong. ultrasonic.

SCHUNK
SONOSYSTEMS
ULTRASONIC WELDING
FOR
WIRE HARNESS




ABOUT US ULTRASONIC WELDING IN THE WIRE HARNESS INDUSTRY
ultra fast. ultra strong. ultrasonic. Ultrasonic metal welding is one of the most important joining technologies employed in the ma-
nufacture of wire harnesses for the automotive, construction equipment and household applian-
Our 400 employees worldwide develop and produce our innovative ultrasonic welding equipment ce industries. Among other things, the process is used for joining multiple wires with each other as
- and together with our representatives we are always close to our customers. In addition to our well as for joining wires with grounding-, high current- and HV-terminals. The wire cross-section
headquarters in Wettenberg (Germany), we have locations in Boston (USA), Toluca (Mexico), Ke- sizes which can be ultrasonically welded ranges from 0.08 mm2 to 280 mm2. Compared with crim-
nitra (Morocco),Taicang (China), Ansan City (South Korea) and Yokohama (Japan). Furthermore we ping or resistance welding, ultrasonic welding offers numerous advantages. These include the
have a worldwide sales and service network. excellent electrical properties of the joint, extremely low energy consumption and comprehensive
process control and corresponding process data management.
APPLICATION AREAS

WIRE HARNESS
¬ Wire - Wire | Wire -Terminal
BATTERY
¬ Battery modules
WIRE HARNESS | WIRE-WIRE
¬ X-/Y-Splices ¬ Li-Ion Technology
¬ Cascade | Mixed-Connections ¬ Capacitors
¬ Ground and high current contacts ¬ Anode/cathode connections
¬ Busbars | Flat Flex Wires ¬ Copper/Tab connections
¬ High Voltage Applications

POWER ELECTRONICS COOLING TECHNOLOGY

¬ IGBT Modules ¬ Copper tubes for refrigeration circuits
¬ IPM Modules ¬ Capillary tubes for thermostats
¬ Cell contacting Systems ¬ EX-certified
¬ Signal Terminals to substrates

SERVICE
¬ Technical advice and support
¬ Process development and integration
¬ Software development
¬ Training system

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WIRE HARNESS | WIRE-WIRE WIRE HARNESS | WIRE-WIRE

MINIC-III L-SPLICE
The Minic-III is the most modern, fastest as well as most user-friendly and low-maintenance ul- ¬ Cross section range:
trasonic welding machine on the world market today. As a benchmark for the worldwide leading 20 mm2 to 100 mm2 (variation 100) resp. 20 mm2 to 200 mm2 ( variation 200)
wire-harness manufacturers, this machine has delivered the best welding results with respect to ¬ Suitable for aluminium, copper and mixed connections (cascade)
strength, Cmk / Cpk as well as the visual appearance of the splices produced, in all applications. ¬ Withstands highest thermal and mechanical loads
¬ Designed for manual operation as well as for integration into fully automatic production systems
¬ Cross section range: 0,26 mm2 to 30 mm2 ¬ Two design variants are available for optimum, ergonomic operation
¬ Suitable for aluminium, copper and mixed connections (cascade) ¬ Wire fixation for manual insertion of wires
¬ Plug & Play functionality through integrated ID chip ¬ Insertion aid optionally available
¬ Sequence welding possible
¬ Easily accessible maintenance and cleaning
¬ Compressed air-free cooling system
¬ Designed for manual operation as well as for
integration into fully automatic production systems

Numerous insertion aids are available for the Minic-III:

Cable fit-in (CFI), welding area illumination, laser posi-
tioning system, pick by light. Please do not hesitate to
contact us.

GLOBAL-SPLICER
Variation | X-SPLICE ¬ Cross section range:
¬ Suitable for welding X- and Y-splices 1,5 mm2 to 40 mm2 (GS-40) resp. 4 mm2 to 50 mm2 (GS-50)
¬ Also available as retrofit kit ¬ Suitable for aluminium, copper and mixed connections (cascade)
¬ All other applications of the Minic-III can also be welded with ¬ Designed for manual operation as well as for integration into fully
this variant automatic production systems
¬ Among other things also constructed for welding twisted wires ¬ Two design variants are available for optimum, ergonomic operation
¬ Short cycletime for mass production (table use)
¬ Insertion aid optionally available
Variation| MINIC-III COMPACTING
¬ Single Wire Compacting
¬ Designed for manual operation as well as for integration into
fully automatic production systems
¬ Suitable for aluminium and copper wires
¬ Best practice in industrial cabinet building

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WIRE HARNESS | WIRE-TERMINAL WIRE HARNESS | WIRE-TERMINAL

DS20-III
With the DS20-III all common terminals in aluminium and copper can be welded. Thanks to an inno-
vative hood concept, the machine is 360° accessible and therefore very easy to maintain.
TERMINAL WELDING
In addition to wire to wire connections, ultrasonic welding is ideally suited for the welding of wires
on terminals. Different material combinations as well as terminal geometries can be welded. The
¬ Cross section range: 2,5mm2 to 60 mm2
result is a connection with extremely high strength and outstanding electrical properties.
¬ Automatic terminal feeding is available in 0°, 90° and 180° versions
¬ Quick and easy tool change

DS20-GT
¬ Cross section range: 1.5 mm2 to 25 mm2
¬ With insulation crimp
¬ Applications in the field of ground terminals

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WIRE HARNESS | WIRE-TERMINAL WIRE HARNESS | WIRE-TERMINAL

DS20-II HECTA
The DS20-II represents a milestone in wire harness production: This machine makes it possible for
the first time to weld wires in this cross-sectional area to terminals. The wires can be connected
to different contact parts with a precision that is unique in this application area. Thanks to an in-
novative hood concept, the machine is 360° accessible and therefore very easy to maintain. H IGH VOLTAGE
¬ Cross section range: 6 mm2 to 120 mm2 E -MOBILTY
¬ Copper, aluminium and mixed connections are possible
¬ With insulation crimp or cutting device
C OMPLEX SHAPE OF
¬ Integration into automated production lines possible T ERMINALS
¬ Optimum accessibility of the welding area
A LLROUNDER

NEW APPLICATIONS

LS-C
¬ Cross section range: 6 mm2 to 200 mm2 NEW POSSIBILITIES
¬ Suitable for numerous terminal applications,
such as tubular cable lugs or bus bars
¬ Welding of copper and aluminium wires to terminals
¬ With insulation crimp and cutting device
¬ Integration into automated production lines possible
¬ Optimum accessibility of the welding area

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 TECHNICAL DATA TECHNICAL DATA
SPLICING MACHINES TERMINAL MACHINES

GLOBAL SPLICER
MINIC-III L-SPLICE DS20-III DS20-GT DS20-II LS-C HECTA
(GEN.2)

20 - 100 mm2 GS40: 1,5 - 40 mm2 CROSS-

CROSS-SECTIONAL SECTIONAL 2,5 to 60 mm2 1,5 - 25 mm2 6 - 120 mm2 6 - 200 mm2 6 - 200 mm2
0,26 - 30 mm2 or or
AREA AREA
20 - 200 mm2 GS50: 4 - 50 mm2

GENERATOR GENERATOR 4 kW | 6 kW | 4 kW | 6 kW |
3 kW 6 kW | 9 kW 4 kW | 6kW 4 kW | 6kW 3 kW 4 kW | 6 kW | 9 kW
POWER POWER 9 kW | 13,5 kW 9 kW | 13,5 kW

FREQUENCY 20 kHz 20 kHz 20 kHz

FREQUENCY 20 kHz 20 kHz 20 kHz 20 kHz 20 kHz
3 x 400 V, N, PE 3 x 400 V, N, PE
3 x 400 V, N, PE 16 A 16 A (6kW) 16 A (4 | 6kW)
POWER SUPPLY or or or 3 x 400 V, N, PE 3 x 400 V, N, PE
3 x 220 V, PE 16 A 3 x 400 V, N, PE 3 x 220 V, PE 16 A (4 | 6 kW) 16 A (4 | 6 kW)
32 A (9kW) 16 A (4kW) 3 x 400 V, N, PE or or
16 A (4 | 6kW) 3 x 400 V, N, PE 16 A
3 x 400 V, N, PE 3 x 400 V, N, PE
COMPRESSED AIR 7 bar 7 bar 7 bar POWER 3 x 400 V, N, PE
or or 32 A (9kW) 32 A (9 | 13,5kW)
SUPPLY 32 A
3 x 220 V, PE 3 x 220 V, PE 16 A
ca. 13 or or
16 A (4kW)
WEIGHT (KG) (incl. cutting and ca. 320 ca. 30 3 x 220 V, PE 3 x 220 V, PE
pneumatic system) 16 A (4 kW) 16 A (4 kW)

COMPRESSED
7 bar 7 bar 7 bar 7 bar 7 bar
AIR

Various options and versions are available for all our splicing and terminal machi-
nes. They can be equipped with features such as a camera, a cooling system or WEIGHT (KG) ca. 300 ca. 150 ca. 600 ca. 900 ca. 1800
an extraction system. There is also the option of different table variants, inser-
tion aids, touchscreens and barcode scanners. Just contact us!

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 OUR LOCATIONS

GERMANY USA
Schunk Sonosystems GmbH Schunk Sonosystems North America
+49 641 803 0 +1 978 658-9400
[email protected] [email protected]

MOROCCO CHINA
Schunk Sonosystems Maroc Schunk Sonosystems China
+212 660 695749 +86 512 53443110
[email protected] [email protected]

JAPAN SOUTH KOREA

Schunk Carbon Technology Japan K.K. Schunk Carbon Technology Ltd
+81 45 470 2339 +82 31 491 2722

100/11-2023 Subject to technical changes and errors excepted. Illustrations similar.

[email protected] [email protected]

All our local support teams

you find on our webpage
www.schunk-sonosystems.com

Schunk Sonosystems GmbH


Hauptstraße 95
35435 Wettenberg
Germany 

+49 641 803 0

[email protected]

www.schunk-sonosystems.com