- EV Tech Insider
- Posts
- Emerson’s new ultrasonic metal welders for EV batteries and electronics, with advanced controls for fast-cycling, high-precision welds
Emerson’s new ultrasonic metal welders for EV batteries and electronics, with advanced controls for fast-cycling, high-precision welds
Emerson has introduced the Branson Series GMX-Micro, a new range of high-precision ultrasonic metal welders.
These welders feature a computerized operating system, multiple power levels and configurations, advanced controls, and enhanced connectivity. The GMX-Micro series is designed to meet evolving material and production requirements for electric vehicle batteries, battery chargers, conductors, and electronics applications. The welders offer faster cycle times, which can boost productivity and lower costs.
The GMX-Micro series is an upgrade from the existing Branson GMX-20MA and GMX-20DP welders. It is available in two power levels: the standard GMX-Micro with 4,000 watts of welding power and the more powerful 5,500-watt GMX-Micro. The latter can be equipped with either a standard metal welding stack or a direct press weld stack, which is designed to exert higher downforce with greater stability. This allows for the completion of complex, multi-layered battery film welds or large-conductor welds with increased stability and consistency.
The GMX-Micro welders come with new power supplies and controls, including an upgraded pneumatic actuation system that resets more quickly (within 100 milliseconds of weld completion). This enables faster weld cycles and higher production rates. The welders also feature rigid polar mounts, dual linear bearings, integral height calibration, and a linear encoder with 5-micron resolution. These features, along with a nodal support design, ensure effective ultrasonic energy transfer and repeatable, high-precision bonding.
The GMX-Micro power supplies (5,500 or 4,000 watt) are managed through a standard 7-inch LCD touchscreen, or optional extended display. This allows users to quickly develop, store, or retrieve weld recipes. The display also graphs critical weld parameters — power, height or frequency — in real-time. The new power supplies also provide extensive weld-quality data capture and storage, multilingual operation, and easy software-based upgrades.
The GMX-Micro series is built on a compact, modular chassis, with two styles based on the choice of normal or direct-press actuator. Both chassis offer expanded working space below the actuator, allowing for easier insertion and removal of larger parts. Weld stacks are also equipped with quick-change tooling to enable rapid production changeovers. Additional connectivity, including 1000/100/10 megabits per second Ethernet, supports real-time data transmission to manufacturing execution systems (MES) or retrieval of stored production recipes via secure internet.
Specifications: