Product Introduction

Precision bonding for power electronics

IGBT module terminals are thin, plated and unforgiving. This cell welds them with a CCD-corrected position loop: the camera finds the substrate fiducials, the X/Y/Z servo axes correct the tooling, and the multi-stage pressure profile lands the bond without cracking the ceramic.

Two stations alternate — welding runs while the operator loads the other side — so the machine keeps a duty cycle no single-station bench can match.

20 kHz / 3000 WDual stationsCCD correctionX/Y/Z servoMulti-stage pressure

Process Flow

What happens in one cycle

Vision-guided alignment, staged force, logged result — every terminal, every time.

1

Load & vision

Operator loads a substrate; the CCD locates fiducials and measures offset.

2

Servo correction

X/Y/Z axes reposition the welding head to the corrected coordinates.

3

Staged weld

Pressure ramps through the profile while ultrasonics run 0.05–9.99 s or the set energy.

4

Log & unload

Result data writes to the 16 G controller store; the second station welds meanwhile.

Dust extraction is built in — plated terminals stay clean through the shift.

Machine Capabilities

What the cell controls

Control axis	Specification	Why it matters
Vision (CCD)	Fiducial-based position correction	Compensates substrate printing and nest tolerances
X / Y / Z servo	Programmable axes	Repeatable head placement across part variants
Pressure profile	Multi-stage ramp	Protects ceramics while achieving bond strength
Weld control	Time 0.05–9.99 s / energy 0.1–30 000 J	Mode per terminal design
Data	In-house controller, RS485 + USB, 16 G storage	Full trace per weld for quality files

Technical Specification

Technical specification

Tooling for your module family — horn and nest sets per substrate — is designed with the trial data.

Qualification path

1

Send substrates or the module drawings.

2

We bond-test and build the pressure profile.

3

FAT with your parts before shipment.

The 16 G store holds every weld’s parameters and curves for your quality records.

Frequency	20 kHz
Power	3000 W
Working stroke	50 mm
Stations	2 (welding + loading/unloading)
Positioning	CCD correction + X/Y/Z servo
Weld time	0.05–9.99 s
Energy mode	0.1–30,000 J
Control	In-house controller, RS485 + USB, 16 G storage
Dimensions	1320 × 1470 × 1620 mm
Weight	≈800 kg
Power supply	220 V ±10%

Suitable Applications

Power-module lines it serves

IGBT Modules

Terminal bonding on power modules for drives and inverters.

Substrate Terminals

Clean, void-free bonds on plated thin terminals.

Batch Qualification

First-article batches welded and documented for customer sign-off.

Recommended Matching Components

Pair with

Generators (2000C / 2000E / H20)

Digital generators with auto frequency tracking — sized to the welder you order.

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Transducers & Converters

High-power piezo stacks 15–40 kHz, capacitance-matched to the generator.

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Sonotrodes & Anvils

CNC-machined, simulated and frequency-tuned for your joint geometry.

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DAS-2060MH 6000 W Welder

Floor-standing cell with weld-depth monitoring — for busbars and CCS boards.

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Customization & Testing

Qualify the cell on your modules

Send substrates or drawings — we build the pressure profile and bond data on your real parts, free of charge.

• Substrate type and terminal geometry
• Terminal material and plating
• Bond strength / resistance spec
• Takt time target
• 3D drawings of module and substrate
• Quality documentation requirements

Send Us Your Requirement Free Process Test

1

You send substrates or drawings.

2

We develop the weld profile and record bond data.

3

You receive the qualification report and FAT plan.

FAQ

Why dual stations?

Loading and welding run in parallel — the operator never waits for the machine.

How does CCD correction help?

It absorbs substrate-to-nest variation, so bond placement stays within microns without a perfect nest.

Can profiles be stored per product?

Yes — profiles and recipes are stored on the controller and recalled by barcode or menu.

Data retention?

16 G on-board storage with RS485 / USB export — every weld is recoverable.

DAS-2060MH6000 W busbar welderSpot WeldersBattery tab weldersMetal Welding MachineFamily overview

Send Substrates, Get Bond Data

Free qualification welds with the full data trail — the shortest path to a confident purchase.

Contact an Engineer

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