The rear of the Telso®Splice TS4, which brings ultrasonic wire splicing to the manual workstation

(Image courtesy of Telsonic)

Telsonic has launched the Telso®Splice TS4, successor to the TS3, pairing ultrasonic wire splicing with a digital welding module and open MES integration at the manual workstation. The system welds copper and aluminium conductors with total cross-sections from 0.26 to 30 mm², and Telsonic lists high-voltage multi-conductor cables among its typical applications, which makes the TS4 relevant to high-voltage cable assembly.

Telsonic ultrasonic wire splicing for copper and aluminium conductors

The TS4 is designed for ultrasonic wire splicing in cable assembly, and because it can sit on a table, a standing workstation or an assembly board, it suits a range of manual set-ups. It handles inline and end splices, centre-strip splices, splice sequences and the compaction of wire ends, working on copper, aluminium and combinations of the two.

Weld quality in Telsonic ultrasonic wire splicing

Quality control starts at the weld itself, where a proportional valve in the welding module controls force directly at the process while a motor adjusts welding width. Monitoring then covers the result, with defect detection working from as little as 3% of strands missing, and because the system exports every weld result continuously, each splice comes with documented quality data.

Welding module and MES integration

The welding module carries its own tool and calibration data, so referencing and self-check run automatically at start-up. When the module needs maintenance or new wear parts, an electro-pneumatic quick-connect coupling lets it swap out without tools in one minute, and the maintenance itself can be done offline. Telso®Assist supports this with Equipment Management, Self-Check and Service Log functions.

Connection to a plant’s MES runs through the optional MES Connector, which includes an OPC-UA interface, or through the Telsonic Production Server, and peripherals such as label printers, heat-shrink machines and taping machines can be integrated alongside. Telsonic designed the TS4 to fit into existing production workflows, and describes its open interfaces as making the system simple and future-proof to network.

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