Two Sonobond machines — a SpliceRite™ Ultrasonic Wire Splicer and a SonoWeld® 1600 Ultrasonic Metal Spot Welder — remained operational after a devastating storm demolished the production area of SolaHD's Rainsville, AL facility. The tornado devastated parts of Rainsville in April 2011.
"This was a catastrophic EF-5 level storm. It directly hit SolaHD, which uses two Sonobond machines in its manufacturing facility," said Sonobond VP Melissa Alleman. "But thanks to the toughness and durability of our made-in-the-U.S.A. equipment, both ultrasonic metal welders survived the tornado even though the roof collapsed on much of that company's production area. In fact, SolaHD was able to put both machines back into operation almost immediately."
The 2500 W SpliceRite™ was totally exposed to the wind and rain when that part of the roof was blown off, yet all it needed was a new foot switch. Both the SpliceRite and the 2500 W SonoWeld® 1600 needed only to be cleaned to remove the water and dirt generated by the tornado. Other than that, both welders were good to go.
Machines Built for a Tough Environment
"Sonobond machines have rugged, industrial-grade frames," Alleman explains. "All our components and subassemblies are carefully checked during the manufacturing process to be sure they will meet the tough demands of a production environment. We also perform multiple welds to ensure the consistency and the quality of the welds before allowing any machine to leave our factory. By producing our ultrasonic metal welders right here in the United States, we can assure our customers that our equipment will give them the maximum in reliability, durability, and performance. I have no doubt that our high manufacturing standards and attention to detail helped the two machines successfully come through the disastrous tornado that hit the SolaHD plant.
"Of course, the really important thing is that no one in the factory was hurt. It is our understanding that only a skeleton crew was on duty when the storm hit. They took cover in the front of the building and were protected by cinder block walls while the EF-5 tornado, with estimated gusts of 200 miles-per-hour or more, lifted the roof, twisted it, and then collapsed it on to the production area. According to published reports, more than half of the plant structure was destroyed and the entire building was damaged. But thanks to the hard work, dedication, and perseverance of SolaHD employees, the factory was back in operation in less than a month. I'm sure the fact that the two Sonobond machines remained operational helped make this remarkable accomplishment possible."
SolaHD, formerly known as Sola Hevi-Duty, is part of Emerson Industrial Automation. The company produces industrial power quality solutions including power supplies, transformers, and uninterruptible power systems.
Sonobond Machines Deliver
Like all Sonobond equipment, the two ultrasonic metal welders used by SolaHD at their Rainsville plant are engineered to deliver outstanding performance, operating without producing arcs, sparks, or fumes and without the use of filler materials. Welds are completed quickly in a single pulse.
The SpliceRite Ultrasonic Wire Splicer (right)?uses controlled pressure to produce true solid-state metallurgical bonds of stranded wire bundles up to 60 sq mm in size. It also splices tinned wires up to 35 sq mm using a 3500 W power supply. It makes strong, high-quality wire connections without clipping, soldering, crimping, or dipping. The machine is perfect for producing the wire bundles found in the automotive, aircraft, computer, and consumer electronics industries and is used in a wide variety of other process control and industrial instrument applications.
The SonoWeld 1600 Ultrasonic Metal Spot Welder (left), available in 1500 and 2500 W models, is suitable for non-ferrous metal spot and wire-to-terminal welding. The SonoWeld 1600 makes the lowest resistance, most reliable electrical connections possible and is ideal for welding foils together or for welding foils to tabs for batteries and capacitors. It can join up to 10 stranded wires from a flat flexible circuit to multi-connection terminals in a single pulse. The machine also welds dissimilar metals, such as copper to aluminum.
Among the applications for Sonobond's SonoWeld series are electrical bus bar fabrication, lithium battery assembly, thin sheet metal welding of aluminum or copper, welding of stranded wire to brass or copper terminals, and assembly of wire harnesses for automotive applications.
Both machines have microprocessors built into the power supply that can store and recall up to 250 weld protocols. These permit welding by time, total energy, or final weld thickness. The two machines also feature tough, heat-treated, tool steel Taper Lock Tips that can perform up to 100,000 welds before being easily removed and replaced.
Wedge-Reed Bonding System
All Sonobond ultrasonic metal spot welders feature the patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is used while the line of force is directly over the parts to be welded, creating a true metallurgical bond that is both precise and dependable. There is no bending stress or stalling.
Sonobond has the only ultrasonic system that is capable of reliable one-pulse welding of most oxidized and tinned metals without pre-cleaning.
Free Ultrasonic Welding Viability Test
Sonobond's free Ultrasonic Welding Viability Test helps customers determine which machine is right for a particular application. Companies are invited to submit their non-ferrous materials to have sample welds made. There is no cost or obligation for this service.
Once the decision has been made to purchase a machine, Sonobond works with the company to ensure a seamless installation, including providing the custom tooling and/or modifications needed to assure optimal results for that application. Sonobond aims to deliver superior service and solid technical support every step of the way — before, during, and after installation.
