Hesse SW985

Smart Welder

Best of both Technologies: ultrasonic welding & wire bonding

Hesse Mechatronics Smart Welder combine the best of two technologies:

  • The force and ultrasonic power of ultrasonic welding equipment
  • The flexibility, precision, speed and advanced process control features of wire bonding machines.

Smart Welder provide producers of medium-sized ultrasonically welded connections with increased process control and freedom of design for the next generation of capable, efficient and cost-effective designs in power electronics, battery packs and other applications.

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Smart Welder

Hesse Mechatronics Smart Welder SW985 combines the best of two technologies: ultrasonic welding & wire bonding

  • The force and ultrasonic power of ultrasonic welding equipment
  • The flexibility, precision, speed and advanced process control features of wire bonding machines.

Smart Welder provide producers of medium-sized ultrasonically welded connections with increased process control and freedom of design for the next generation of capable, efficient and cost-effective designs in power electronics, battery packs and other applications.

The new Smart Welder by Hesse include precise positioning and rotation between welding tool and product, image recognition to detect the exact weld location, and derivation of an optimal trajectory to reach the weld location quickly and very precisely.

Together with long and narrow welding tools, this allows very tight spacing and thus compact products, higher power density.
Further advanced functions include touchdown sensing, precise and dynamic contact force control, diverse process control features such as monitoring of ultrasound characteristics and deformation (cf. DVS 2811), and standardized interfaces for assembly line integration.
Smart Welder can, like ultrasonic wire bonders, flexibly handle a large variety of products. New products only require a program change and possibly adapted clamping and automation.

Advanced features and process advantages

  • Better UPH: Only one welding point instead of a complete connection
  • Unbeatable in positioning and clearance
  • Image recognition for detection and correction of the weld location
  • Active vertical axis
  • Wide range of US power (for flex PCB up to leadframe applications)
  • Narrow pitch and deep access due to long, narrow welding tools and pattern recognition supported positioning
  • Perfect US exposure by rotating weldhead
  • Touchdown sensor to avoid damage to sensitive contact partner
  • Precise and dynamic force control
  • Programmable welding maps with multi interval processes
  • Individual parameters per spot
  • Flexibility to handle a large variety of products
  • Standardized interfaces for line integration
  • Automotive accepted process control (PiQC, patented)
  • Automated bondtool calibration without wedge gauge
  • Wear-free components with Piezo technology
  • Maintenance-free solid state joints
  • Pre-setting of weldheads


  • Working area: up to 370 mm x 560 mm
  • Flexible use of the working area, e.g. vacuum clamping
  • Maximization of throughput by automation (two/more parallel lanes)


  • Process integrated Quality Control PiQC: detection of further parameters, e.g. friction behavior, by additional sensor system for 100 % quality monitoring in real time (patented); as option

Working area

  • SW985: X: 370 mm; Y: 870 mm; Z: 42 mm
  • P-axis and rotation: 440°
    (only for hybrid machines)

Mechatronic weldhead

  • From 200 W up to 1500 W


  • Wide range of US power
  • Digital ultrasonic generator with PLL (Phase Locked Loop),
    internal frequency resolution <1 Hz
  • Programmable ultrasonic power output

Footprint and weight

  • SW985: 880 mm x 1780 mm x 1912 mm, (W x D x H, excl. monitor and light tower), appr. 1800 kg

PiQC – Process integrated Quality Control

The Hesse GmbH has implemented a new Process integrated Quality Control system (PiQC) that is unique to the global wire bonding market. A sensor integrated into the transducer allows for the first time a multi-dimensional signal analysis of the bond process. PiQC calculates a bond quality index value in realtime, using significant signals from the wire bonding process.

Advantages for volume production

  1. Inspection of every bond
  2. No mechanical load of the bond connection
  3. Product specific configuration of the quality control system

Feedback from the process

  • Mechanical oscillation of the wedge
  • Friction at bond surface
  • Transducer current
  • Ultrasonic frequency progression
  • Wire deformation

Quality statements by PiQC

PiQC calculates a quality index for each bond based on the actual feedback signal from the process.
The signal related components of the quality index can be displayed graphically at any time.

Teach mode for reference data

  • Detailed automatic analysis of the welding process
  • Extraction of process-specific reference data

Numerous software features extend the portfolio Hesse machines and meet the growing demand of connectivity and industry 4.0.

Find out more about the individual functions.

Hesse Bonder Network HBN 1000 - MAchine Interconnectivity and Synchronisation

Hesse Bonder Network HBN 1000: complete line management, synchronization of data, easy integration of new machines via Plug & Produce, no server necessary

The Hesse Bonder Network is a decentralized solution for the interconnectivity of machines and the distribution and synchronization of data amongst the bonder within the network. The distribution of the various data can be set individually.

The HBN 1000 enables also the easy integration of new machines into existing production lines. This is supported by a controlled synchronization. Line management can be handled from any of the connected wire bonder. Production programs, libraries of material and general settings are automatically adopted from existing machines. A super-ordinate server system or a manual transfer or copying is no longer necessary. Beyond these advantages, the installation of such a bonder network is a benefit for the security of data and production. Decentralized data storage minimizes the risk of a black-out.

„Plug and Produce“ with HBN 1000

Steps of an easy integration

  1. Assign a bonder to a line („line configuration“)
  2. Specify the bonder for synchronization („local settings“)
  3. Define the synchronization („synchronized data“) and the settings („synchronization settings“)
  4. Use dialog „file import/export“ to select or share recipes, settings or process programs
  5. Finish and confirm the sychronization


Workbench 2.0 : Wire Bonder Server for PBS & PiQC

PBS Server & Workbench 2.0: central data management, line management, automatic backup system, remote pattern recognition

The Workbench 2.0 software is the graphical user interface for the PBS server and enables the display and evaluation of process data.

The PBS server (Windows™ based system) links up to 20 Hesse Mechatronics wire bonder together. The machines can be supervised and administrated while production is running. PBS provides perfect integration of the wire bonder into the production system.

Workbench 2.0 receives and visualizes process data from various sources (quality data from the PiQC database, process data and files from PBS). All data is exported to popular formats for further processing. The Workbench enables file transfer in order to transmit bond programs and parameters from machine to machine.

Line management with material overview and indicator
Realtime view

Advanced features and process advantages

  • Line management
    Display of all bonder with current status, characteristics and material consumption indicator (e.g. replace wire spool, wedge change etc.)
  • User management
    Create, change, delete user accounts. Assignment of user accounts to individual wire bonders or production lines
  • File transfer
    Bidirectional between bonder and local workstation
  • Process data
    Display of all process data of all connected wire bonder. Storage and data export in common fomats
  • Data backup
    Configuration of timed and regular data backup of all wire bonder data
  • RAW data view
    Recorded PiQC quality values and sensor curves with filter options
  • Realtime view
    Display of all quality values in real time
  • Teach score
    Traceability of the teach procedures
  • Master programming
    Load process programs directly from the PBS Server. Ensure that the wire bonder run only the latest released process programs
  • Multi Server
    Run multiple PBS servers and administrate all with the Workbench in your office
Offline Programming

Offline Programming

Offline programming allows you to program bond programs outside the bonder and outside the production environment. It prevents production interruptions and brings significant benefits in terms of quality, resources, costs and deadlines. Capacity and cycle times can also be optimized with offline programming.

The solution for this is the Hesse software for offline programming. The software represents the exact graphical interface of the bonder and runs under Windows 10.
Functions for the complete process are available:

  • Import of process data
  • Offline programming
  • Simulation and optimization
  • Export and installation of programms onto the bonder

Offline programming simulates the control of the machine hardware, the ultrasound system and the live views with lighting and focusing of the loaded camera image. Product images can be scanned from existing bonders (prefered) or generated from CAD data.

The integrated online help supports the user during the complete process.

After finishing the offline programming, the data can be conveniently transferred to the bonder in different ways:

  • USB stick
  • Hesse Bonder Network (HBN)
  • PBS server
  • Network Drive

In addition to its use in everyday production, offline programming also offers advantages for training purposes.

TwinCAT Automation

Integration of control software for automation in Hesse Bonder Interface with TwinCAT® Automation

    • Hesse automation systems are based on Beckhoff PLCs which are controlled via TwinCAT
    • TwinCAT enables a machine to communicate with the automation hardware
    • The automation user interfaces (setup, production screen) are integrated in the Hesse Bonder Software
    • Hesse Bonder Software option for TwinCAT is able to integrate any  TwinCAT 3 based automation system

SECS/GEM: integrated standardized server

SECS/GEM: integrated standardized server connection for automation and communication, handling via Workbench

  • Communication of a bonder with a SECS/GEM host
  • Process program management
  • Remote control
MES Interface

Interface to Manufacturing Execution Systems, integrated or customized implementation

  • Integration of Hesse bonder into customer´s proprietary MES infrastructure
  • Functions: communication of process data or events, validation of incoming material identifiers or association of process results with a material identifier
CSV Logger

CSV Logger: storage of all machine and process data, e.g. bond positions etc.

The CSV logger stores all machine events and related data to a CSV file. For instance for each bond that is made, its positions as well as related process data (variables) are recorded. More than 490 variables can be logged!.

The created files are freely configurable to customer’s needs and log ongoing by triggering events. Example: The CSV logger function can be configured to create a file logging errors but also a file containing the bonded assemblies including its PiQC values.

Easy Login via USB Stick

Easy Login via USB Stick

A specially prepared USB stick acts as an access key. You can log into the bonder without entering the password and have direct access.

Automation Solutions

The precise and safe handling of the products in and out of the production machine plays a significant role in controlling the product quality, yield and efficiency of the production equipment. For this reason Hesse GmbH is offering automation concepts individually adapted for every application.

Transport system

Transport system

All machines of Hesse GmbH can be equipped with a standard transport system or a customized version for a fully automated manufacturing in production lines or cells. In addition to single products and/or multi panels also Auer boats or other kind of product carriers can be used on the transport lane. As a service, the Hesse GmbH provides the design and manufacture of customized product carriers.

Basic design

  • Transport system consisting of one segment with a bonding station
  • Manual adjustable transport rail width
  • Transport direction is from left to right
  • Product detection by sensors
  • Belt drive with stepper motor (belts antistatic coated)


  • Transport system e.g. with 3 segments: Input buffer, bonding station and output buffer (Input and output buffer can also be used as preheat station or postheat station to cool down slowly)
  • Transport systems with 2 or 3 lanes for parallel processing and transportation of products
    • Dual lane system with shuttle transport for parallel using of several bond stations
    • Additional bypass lane through the machine to increase the line availability at maintenance work or to optimize the index times for production cells with more machines
  • Automatic adjustable rail width of the transport lane
  • Linear drive with gripper for high throughput
  • „Walking beam“ for Auer boats or product carriers
Magazin lifts

Magazine lifts

All machines of Hesse GmbH can be equipped with magazine lifts for the setup of manufacturing cells or islands. Our standard solution consists of simply attached lifts to the transport system, with the advantage of a cost-effective solution and optimum footprint.

Basic design

  • Integrated width adjustable magazine lifts each for 1 magazine up to max. 18 kg
  • Pusher for loading and unloading of products
  • Magazine detection


  • Short-pusher version with press rollers on the transport system
  • Belt drive in the magazine for transfer to the transport system
  • Slot monitoring at the magazine
  • Magazine clamping
  • Integrated lifts with capacity for several magazines
  • Material handling systems with several lanes
  • Stand-alone-lifts
Bonding Station

Bonding station

The core piece of the automation in the Hesse GmbH machine is the bonding station with its individual design layout and clamping principle. In general, the bonding station is disconnected from the transport system to prevent external influences and to ensure optimal bonding conditions. For different products or product carriers standard solutions have been developed, based on this special solutions can be developed.

Basic design

  • Lifting cylinder with position monitoring
  • Clamping with vacuum and vacuum monitoring
  • Offbond station


  • Vacuum and mechanical clamping
  • Bonding station with heating to 250°C
  • Vacuum monitoring and circuit in separate circles
  • Tool-less quick-change system for product clamping
  • Additional heated bonding station incl. vacuum sensor


By default, the operation of the automation of Hesse GmbH occurs via the machine interface including graphical representation of the current process state. In addition, an optional touch screen for complex automation systems and solutions are used with extended capabilities. Using a graphical user interface the production and setup can be visualized with manual control.

Visualization in automatic operation / production mode:

  • Display of the machined magazine slot
  • Display of the transport segment (preheating, bonding station, etc.) in which the product is located currently
  • Scanned barcode of the product; such as scanning order data
  • Temperature of heating (with monitoring function of the target state)

Visualization and control in manual setup / setup mode:

  • Current status of the sensors
  • Position of the axes
  • Manual control of the entire automation system (e.g. motion of the bonding station, and/or operation of the vacuum)
MES Interface

MES Interface

We are able to realize a connection to any MES (Manufacturing Execution System). Product information such as bond program or rework data are determined and process results are returned for every product. The setup condition of the machine can be validated and parameters of automation can be received. MES connections are always realized as customer specific solutions.

Examples / options for MES-interfaces:

  • Connection to customer database
  • Connection to existing systems or MES server (such as iTAC)
  • Development of customized solutions
  • Individual solutions for connection to SECS / GEM host

Smart Welder SW985 Datasheet