Ultrasonic Welding for Superior Electrical Conductivity
At Herrmann Ultraschall, our consulting services are designed to uncover hidden opportunities for significant efficiency gains and improved product performance. We recently partnered with a leading electrical connector manufacturer, where our expertise in ultrasonic welding revealed a superior alternative to their traditional crimping process. This collaboration led to a remarkable improvement in electrical conductivity and connection reliability, demonstrating the power of innovative solutions.
Our Sales Director delivered a personalized solution by showcasing how ultrasonic welding would specifically provide their connections with significant improvements in electrical resistance, mechanical strength, and overall reliability.
The challenges
- The client was experiencing electrical resistance and power loss in their crimped connections, indicating an inefficient power transmission.
- Traditional crimping methods suffered from "crimp relaxation," causing connections to loosen over time, leading to increased electrical resistance, intermittent connections, and potential electrical failure.
- Applications in critical sectors like data centers and electric vehicles demand exceptionally low resistance for maximum power and reliability, which traditional crimping struggled to consistently provide.
- Traditionally crimped lugs begin to deteriorate over time, resulting in increased electrical resistance.
Our solution
- Herrmann Ultrasonics introduced ultrasonic welding as a superior alternative, utilizing high-frequency vibrations to create a robust metallurgical bond between conductors and lugs.
- This innovative approach eliminated "crimp relaxation," ensuring a more unified and consistent electrical current path with significantly reduced electrical resistance and improved durability.
- Data from a third-party study highlighted the clear advantages of ultrasonic welding, showing a significantly lower average resistance change over time compared to crimped connections, ultimately delivering enhanced performance and reliability.
Customer benefits
By implementing ultrasonic welding in their manufacturing process, the client gained the significant advantage of delivering a premium product to their customers. This allowed them to cater specifically to highly sensitive applications demanding high power connectors with zero downtime, ultimately ensuring superior performance and reliability in critical systems.
Consulting as a Success Factor
Our direct, on-site consultation and expertise allowed us to not only identify root causes of client challenges, such as electrical resistance and "crimp relaxation," but also to effectively demonstrate the clear advantages of ultrasonic welding. Our ability to present compelling evidence, including detailed study data, is a key factor in showcasing how our innovative solutions can directly address customer pain points and unlock a new level of efficiency and product quality. So feel free to contact us today to develop a customized solution for your business needs!
Find out more in the complete customer story
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Contact our team to discover how our premium solutions can elevate the quality and effectiveness of your large-scale manufacturing. We look forward to hearing from you!