Ultrasonic welding systems and methods of using the same

A method of operating an ultrasonic welding system, the method comprising the steps of:

• assembling a workpiece at a workpiece assembly station of the ultrasonic welding system, the workpiece comprising a power module, the step of assembling including aligning a contact element of the workpiece with a base structure of the workpiece;
• supporting the workpiece on a support structure of the ultrasonic welding system;
• and
• welding at least one conductive contact of the contact element of the workpiece to a conductive region of the base structure of the workpiece using a weld head assembly including an ultrasonic converter carrying a sonotrode to form an ultrasonic weld between the at least one conductive contact and the conductive region, the conductive contact having a thickness between 0.2-3 mm, the weld head assembly being moveable along a plurality of substantially horizontal axes, the sonotrode welding the at least one conductive contact of the contact element of the workpiece to the conductive region of the base structure of the workpiece during a welding operation at a bond force of between 5-500 kg, and with a sonotrode tip motion amplitude of between 5-150 microns, the ultrasonic weld having an area in a range between 1.5-30 mm2.