Summary
- Telsonic’s torsional SONIQTWIST® welding technology used for fixing silver-plated aluminum busbars with screws
- Collaboration with KERN-LIEBERS Group for innovative solution in electrical connections for industrial applications
- Coating aluminum busbars with silver enhances conductivity but poses challenges for secure attachment
- Solution involves integrating a copper sleeve into the busbar for durable and conductive connection
- Telsonic’s torsional SONIQTWIST® technology successfully implemented for reliable and conductive connections in industrial applications
Article
Telsonic’s advanced torsional SONIQTWIST® welding technology has been utilized in a groundbreaking solution developed in collaboration with the KERN-LIEBERS Group for securing silver-plated aluminum busbars using screws. This innovation aims to set new standards for reliability and conductivity in electrical connections for industrial applications. The challenge arises from the relaxation properties of aluminum when coated with silver, making it difficult to securely attach screws. The solution involves integrating a copper sleeve into the busbar to provide a durable and electrically conductive connection that allows for screw fixation.
The KERN-LIEBERS Group has pioneered a technique to coat aluminum busbars inline with silver to enhance their conductivity. To address the challenge of securely attaching screws to these silver-coated busbars, a copper sleeve is integrated into a pre-punched hole in the busbar. The design of the copper sleeve includes an oversized collar to facilitate the transmission of torsional ultrasonic vibrations through a sonotrode, effectively welding the sleeve to the silver layer to maintain the integrity of the silver coating.
The integration of silver coating expands the compatibility of ultrasonic welding to new aluminum alloys, offering a process-secure and long-term stable connection between dissimilar metals with minimal electrical resistance. The production of busbars with punched holes is cost-efficient, and integrating the silver coating into the production process eliminates additional transport costs for external coating. This innovative solution demonstrates the versatility and effectiveness of ultrasonic welding in creating reliable and conductive connections in industrial applications.
The successful implementation of this solution was achieved using Telsonic’s torsional SONIQTWIST® technology, specifically the torsional welding system TSP3000. This technology showcases Telsonic’s capability to meet the demanding requirements of industrial applications by ensuring reliable and conductive connections. The use of torsional ultrasonic welding with the TSP3000 system enables the secure attachment of screws to silver-plated aluminum busbars, providing a durable and electrically conductive connection that meets the high standards of reliability required in industrial applications.
Overall, the collaboration between Telsonic and the KERN-LIEBERS Group in developing a solution for securing silver-plated aluminum busbars using screws demonstrates the innovative potential of advanced welding technologies in addressing complex challenges in industrial applications. By integrating copper sleeves with ultrasonic welding and leveraging the capabilities of torsional SONIQTWIST® technology, a reliable and conductive connection can be achieved, setting new standards for reliability and conductivity in electrical connections for industrial applications. This solution not only enhances the performance of aluminum busbars but also improves the efficiency and cost-effectiveness of the production process.
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