iSONIC ECO CUBE MEC
Ultrasonic Wire Compactor for Cable Processing

Ultrasonic wire compaction: compact cable ends with ultrasonic technology

The iSONIC ECO CUBE MEC compacts flexible single wires and multi-core cables into compact and stable cable ends. The wires are compacted from all sides, creating a defined, round geometry. Unlike conventionally compacted wires with a more rectangular shape, the round cable ends can be easily inserted into safety terminals and control cabinet terminals.

Depending on the application, the compacted cable ends can be inserted directly into terminals, eliminating the need for wire-end ferrules. This reduces process steps and simplifies subsequent electrical processing.

 

Precise. Repeatable. Efficient.

The wire is positioned between the sonotrode and anvil and compacted ultrasonically under defined pressure. High-frequency vibrations bond the individual wires into a homogeneous cable end. The process delivers consistent and repeatable results.

The ultrasonic generator with 3 kW output power and a 20 kHz operating frequency is specifically matched to the process. Up to eight insertion sleeves enable the processing of different wire cross-sections and allow for quick adaptation to various applications. The processable cross-section range is 0.3 to 4.0 mm².

 

Advantages

• Optimized geometry: Wires compacted from all sides into a defined, round shape for easy insertion into safety and control cabinet terminals
• Fewer process steps: Depending on the application, no wire-end ferrule or additional termination material is required
• Consistent quality: Defined process conditions for repeatable results
• Flexible application: For flexible wires and multi-core cables with cross-sections from 0.3 to 4.0 mm²
• Easy integration: Space-saving machine concept for different production environments
• Efficient process: No additional consumables required

Applications

• Cable processing: Repeatable cable ends for high-volume and small-batch production
• Control cabinet manufacturing: Compact cable ends for direct further processing
• Electrical and electronics manufacturing: Process-reliable and repeatable electrical connections
• Machine and plant engineering: Reliable processing of flexible cables

Typical Applications

• Ultrasonic compaction of copper wires
• Ultrasonic compaction of flexible cables
• Producing cable ends for subsequent electrical processing
• End compaction for control cabinet terminals

Process

• Ultrasonic end compaction
• Ultrasonic welding

Standard machine concepts

iSONIC ECO iSONIC ECO TM iSONIC ECO CUBE LIFT iSONIC ECO FLEX iSONIC ECO HSG iSONIC ECO CUBE iSONIC ECO CUBE MWL iSONIC ECO CUBE MTC

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