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Publication Date: 06/1/2011
Archive >  June 2011 Issue >  Electronic Mfg. Services > 

Cornell Dubilier: High Marks for Sonobond, Adds New Ultrasonic Spot Welder
SonoWeld® 1600 Series Metal Spot Welder can weld up to eight layers of foil with a single pulse.

Capacitor manufacturer Cornell Dubilier relies on Sonobond Ultrasonics technology to weld multiple layers of foil to capacitor posts. The process helps ensure that the capacitors are produced quickly and conform to the highest standards of dependability.

The company has been very pleased by both the performance of Sonobond's equipment and by its commitment to helping CD find customized welding solutions. As a result, Cornell Dubilier is in the process of adding a SonoWeld® 1600 Spot Welder to its Liberty, South Carolina facility. The new unit will give the company the capacity to weld even more layers of foils to the capacitor posts — all in a single pulse.
Cornell Dubilier has years of experience using Sonobond ultrasonic spot welders to attach multiple layers of foil to capacitor posts.

According to Tom Crumpton, Production Superintendent at Cornell Dubilier, "Sonobond technology is quick and dependable. It delivers repeatably excellent welds. In addition, Sonobond provides fast, reliable technical support. I'd rate their performance as practically a `10'. You can't do better than that! We especially commend Sonobond for their ability to provide the specialty tooling for our specific spot welding requirements and for responding promptly to our questions and requests. This combination of outstanding technology and hands-on commitment to good service has made us eager to add the new SonoWeld 1600 to our production capabilities."

Patented Wedge-Reed System
Ultrasonic metal welding is fast, cost-effective, and environmentally-friendly. It creates solid-state metallurgical bonds without the use of heat, current, fluxes, or fillers. The process utilizes a welding tip to direct high-frequency ultrasonic energy to the surface between the metals being welded. The vibratory energy disperses the oxides and surface films between the work pieces to produce a bond without melting the materials. However, Sonobond metal spot welders, such as those used by Cornell Dubilier, give manufacturers an important added advantage over other types of ultrasonic metal welding equipment. That's because the company uses its patented Wedge-Reed bonding system that combines high vibratory force with low amplitude coupling to produce maximum metal welding effectiveness. The Wedge-Reed system achieves highly dependable welds because it utilizes shear mode vibration that is parallel to the welding surface. Bending stress is eliminated by positioning the line of force directly over the welding surface. Non-ferrous similar or dissimilar metal assemblies can be confidently welded, including copper to aluminum. Even lightly tinned or oxidized metals can be accommodated.

Digital Metal Spot Welder
The 2,500-watt unit being added by Cornell Dubilier is described as an easy-to-use, microprocessor-controlled metal welding system that offer multi-function capabilities never before available in a single ultrasonic welder. It performs spot welds in a single pulse and with repeatable accuracy. This includes welding multiple layers and/or delicate foils to tabs or terminals. The addition of special tooling enables the unit to provide wire-to-terminal welding.

A microprocessor built into the power supply can store and recall up to 250 weld protocols from memory. Weld parameters can be set up by time, total energy, or final weld thickness. The unit, which is available as either a 1,500-watt or 2,500-watt model, has an RS-232 port to transfer weld data to a computer. Automatic control monitoring detects when variables exceed preset power and time limits. It also senses if a part height is different from that originally set, as well as wrong-part or no-part welding.

According to Scott Day, Electronic Technician at Cornell Dubilier, the decision to add a SonoWeld 1600 with an FC2026 power supply to the company's production line was the result of careful consideration. He says, "Although we gave thought to other systems, we're very pleased by the excellent results we've been getting from the Sonobond ultrasonic welding equipment we currently use. Before the introduction of Sonobond equipment some time ago, the company had used mechanical welding methods."

For the manufacturing operation at Cornell Dubilier, the ultrasonic spot welders provide speed, design, and ease of maintenance, and require only minimal training. "In addition," says Day, "technical support staff does an excellent job of providing any help we need in making sure our units work at peak efficiency."

QC Features
In discussing installation of their new Sonobond unit, Mr. Day goes on to say, "W're especially impressed by the feedback loop feature of the SonoWeld 1600. This feature will tell us how much power we've used to make a weld. If our set points are met, we know we've gotten the quality weld we require. In other words, the SonoWeld 1600 will not only provide us with fast, repeatably accurate welds, it will also help ensure that our capacitors continue to adhere to Cornell Dubilier's exacting standards."

Although the Metal Spot Welder is capable of welding up to eight layers of foil, Cornell Dubilier currently uses its Sonobond equipment to weld a maximum of four layers to its capacitor posts. However, as the company continues to evaluate the possibility of eventually increasing this. The SonoWeld 1600 will provide the added capacity in the future without requiring a change to another model.

Contact: Sonobond Ultrasonics, 1191 McDermott Drive, West Chester, PA 19380 800-323-1269 or 610-696-4710 fax: 610-692-0674 Web:

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