Sonobond's American-Made Ultrasonic Metal Welders are Tough Enough to Survive Even an EF-5 Tornado
Two Sonobond machines-a SpliceRite(TM) 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, Alabama facility.
WEST CHESTER, Pennsylvania - Sonobond Ultrasonics announced today that two of its ultrasonic metal welders survived the full force of the tornado that devastated parts of Rainsville, Alabama in April, 2011.
According to Sonobond Vice President Melissa Alleman, "This was a
catastrophic EF-5 level storm. It directly hit SolaHD, which uses two Sonobond
machines in its manufacturing facility. 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.
"One of the Sonobond ultrasonic metal welders-a 2500-watt SpliceRite(TM)-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. The SpliceRite and the second machine-a 2500-watt
SonoWeld® 1600-just had to be cleaned out to remove the water and dirt produced by
the tornado. But other than that, both welders were good to go."
Machines Built for a Tough Environment
Ms. Alleman goes on to say, "Sonobond machines have rugged, industrial-grade
frames. All our components and sub-assemblies 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 Outstanding Results
Like all Sonobond equipment, the two ultrasonic metal welders used by SolaHD
at their Rainsville plant are carefully engineered to deliver outstanding performance.
These machines operate 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 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-watt
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. It is also used in a wide variety of other process control and industrial
instrument applications.
The SonoWeld 1600 Ultrasonic Metal Spot Welder is available in 1500-watt
and 2500-watt models. It is ideal for non-ferrous metal spot and wire-to-terminal
welding. The SonoWeld 1600 makes the lowest resistance, most reliable electrical
connections possible and is perfect for welding foils together or for welding foils to tabs for batteries and capacitors. This equipment 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 many applications for Sonobond's SonoWeld series are electrical bus bar fabrication, lithium battery assembly, thin sheet metal welding of aluminum or copper, the welding of stranded wire to brass or copper terminals, and assembly of wire harnesses for automotive applications.
Both the SpliceRite and the SonoWeld 1600 have microprocessors built into the
power supply that can store and recall up to 250 weld protocols. These permit welding
Page 4 - Sonobond's Ultrasonic Metal Welders Survive EF-5 Tornado 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.
The Unique, Patented Wedge-Reed Bonding System
All Sonobond ultrasonic metal spot welders feature the unique, patented Wedge-
Reed bonding system of high vibratory force and low amplitude coupling. Shear mode
vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded. This creates 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
Thanks to Sonobond's free Ultrasonic Welding Viability Test, it is easy to
determine which machine is right for a particular application. Companies are invited to
submit their non-ferrous materials to Sonobond 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 that the installation is as seamless as possible. This includes
providing the custom tooling and/or modifications needed to assure optimal results for
that application. Customers can count on Sonobond for superior service and solid
technical support every step of the way-before, during, and after installation.
Over 50 Years of Innovation and Leadership
Sonobond is a global leader in the application of ultrasonic welding and bonding
technology. It was in 1960 that the company-then known as Aeroprojects-received
the first patent ever awarded for ultrasonic metal welding. Over the intervening 52
years, Sonobond has established and maintained an outstanding reputation for its
pioneering work and quality-engineered products. The company's many customers
include leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, and ballistics industries. Sonobond equipment is environmentally-friendly and easy to operate with only minimal training.
Contact Us for Additional Information
To learn more about Sonobond products or for information about the free, noobligation
Ultrasonic Welding Viability Test, call 800-323-1269 or visit the company's
website at www.SonobondUltrasonics.com. For immediate service, contact Vice
President Melissa Alleman at MAlleman@SonobondUltrasonics.com.
