MPX Metal Welding Technology

MPX Metal Welding Technology

Versatile And Scalable Ultrasonic Welding For The EV Sector

Christian Huber

The rapid growth of the EV market has brought with it a wide range of welding and joining applications on the various cables, connectors, terminals, and contacts associated with the power-train components and batteries required for electric vehicles of all types.

(The modular design of Telsonic’s MPX makes it suitable for multiple metal welding tasks in different configurations)

In its simplest configuration, the individual components which make up the MPX can be seamlessly integrated into automation lines. A standard OPC UA interface provides the connectivity to access all the relevant information. This gives integrators maximum flexibility and control of the process at all times. In addition, a secure VPN connection provides remote access. Alternatively, MPX is available as a semi-automated, stand-alone system, ergonomically designed to provide easy access to the work area, enabling operators to carry out their tasks consistently without fatigue. In this configuration, the MPX welding press is ideally suited to small batch production runs, yet still capable of delivering high levels of productivity. The process parameters developed on this system can easily be transferred to a fully automated system seamlessly and without the need for changes or alterations. MPX modules can also be used for manual-workstations for spot-welding applications on cables and battery components.

The capability to select from and add a series of standard modules, allows more complex tasks to be undertaken, such as welding terminals that are automatically fed. The system can be re-configured in just a few minutes, a valuable feature for small batch production, providing the flexibility needed for the manufacture of different product variants. Furthermore, the different modules are robustly designed, making them ideally suited to 24/7 operation.

(It is possible to add a series of standard modules to the MPX System)
(It is possible to add a series of standard modules to the MPX System)

“The diversity of different EV applications, combined with the need to be able to increase production volumes as projects move from initial development into full scale manufacturing requires technology with the flexibility to adapt to changing needs”

During production, the Telso®Flex enables continuous quality monitoring. The system detects trends, which means that potential production errors can be quickly identified and avoided. Operators also have the option of adjusting batch sizes if required. In addition, the software provides operators with valuable information and topic-related assistance, minimising downtime for service or maintenance.

(The 12” touchscreen provides an intuitive interface for the user)
(The 12” touchscreen provides an intuitive interface for the user)

Process consistency is essential if high quality levels are to be achieved and maintained, and Telsonic’s MPX technology achieves this through the delivery of precise welding power and displacement. Using a combination of “Energy”, “Time”, and “Distance” welding modes, and thanks to multi-stage welding profiles, Telso®Flex software provides the flexibility required to define solutions for even the most complex applications. The parameters and results for each weld are recorded and can be exported for offline storage on network drives or FTP servers. Any deviation from standards, will result in the product being rejected to a scrap box using a wire cutter which prevents rejects being inadvertently re-used.

“Process consistency is essential if high quality levels are to be achieved and maintained, and Telsonic’s MPX technology achieves this through the delivery of precise welding power and displacement

The system can be re-configured in just a few minutes, a valuable feature for small batch production, providing the flexibility needed for the manufacture of different product variants”

The comprehensive range of standardised features and modules available as part of the MPX portfolio include advance stroke with two force levels, four power levels from the welding generator, part positioning, wire position detection, wire clamping, insulation crimping unit, automated terminal feeding and a wire cutter.

Christian Huber Product Market Manager Metal Welding Telsonic

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