Abstract: An ultrasonic tab welder, useful for welding metal ribbon to metal sheet, has an ultrasonic stack having a horn configured to include a pair of ends between which are one or more upstanding welding stud surfaces and held by a bracket assembly. The bracket assembly includes a horn holder terminating at either end with U-shaped legs holding either end of the horn and an upper U-shaped legs having a generally horizontal piece carrying a strain gauge. A T-shaped assembly mated with the horn holder U-shaped legs that are carried by a U-shaped holder by a pair of downward holder legs. A pair of ball bearing assemblies are captured between the downward holder legs, the upper holder U-shaped legs, and the horn holder up U-shaped legs. The horn upstanding welding stud surfaces conformingly mate with the metal ribbon as it is welded to the metal sheet.

Abstract: An ultrasonic welding assembly joins bare ends of an insulated wire bundle to a wire terminal in a weldment zone by intimate contact with a sonotrode of an ultrasonic stack. A door allows the operator to place the terminal into the nest within the weldment zone. One operator hand holds the wire bundle while one contacts an external sensor. A pair of terminal clamps extend inwardly and down to secure the terminal and create a taller capture area for the loose bare wire ends. A pair of clamp finger assemblies reversibly extend towards the insulated wires away from the weldment zone for securing the wires. A wire gatherer descends upon and captures all of the wire bare ends and secures them until the horn descends, captures, and holds the wire ends in place, then extends away from the weldment zone for ultrasonic welding to commence.

Abstract: An ultrasonic welding assembly joins bare ends of an insulated wire bundle to a wire terminal in a weldment zone by intimate contact with a sonotrode of an ultrasonic stack. A door allows the operator to place the terminal into the nest within the weldment zone. One operator hand holds the wire bundle while one contacts an external sensor. A pair of terminal clamps extend inwardly and down to secure the terminal and create a taller capture area for the loose bare wire ends. A pair of clamp finger assemblies reversibly extend towards the insulated wires away from the weldment zone for securing the wires. A wire gatherer descends upon and captures all of the wire bare ends and secures them until the horn descends, captures, and holds the wire ends in place, then extends away from the weldment zone for ultrasonic welding to commence.