The Application of Ultrasonic Welding of Large Square High-voltage Wire Harness Terminals

Long battery charging time is one of the key factors limiting the growth of the electric vehicle market.

In order to shorten the charging time of electric vehicle batteries, electric vehicle manufacturers need to improve the ability of the circuits in the charging system to carry high voltage and large current, which relies on cables with large current carrying capacity.

Therefore, wire harnesses with large cross-sectional areas are widely used to flow higher currents and also have good heat dissipation capabilities. They are an effective method to improve the charging efficiency of electric vehicle batteries.

In the future, the current carrying capacity of high-voltage wiring harnesses for electric vehicles will be four to five times that of existing ordinary electric vehicle cables. In terms of wire harness size, if copper is selected as the conductor material, the cross-sectional area of the wire harness used will increase from 50mm² to 200mm², or even higher.

How can these cables with larger cross-sections be reliably connected?

As an efficient solid-phase connection process, the ultrasonic metal welding process has the advantages of short welding time, low internal resistance of the joint, and high mechanical strength. It is especially suitable for the welding of key wire harnesses or wire harnesses or wire harnesses and terminals in high-voltage connector systems.

However, ultrasonic welding of high-voltage wire harnesses with large cross-sectional areas (≥50mm²) requires the use of very high-power equipment, and at the same time, the mechanical strength of the welded wire harness and connectors must be ensured during use.

Ultrasonic welding has higher-precision pressure sensors and displacement sensors, which can detect and control the welding process more accurately.

For welding quality monitoring, the equipment can be connected to the customer’s MES system so that the entire process parameters can be recorded and traced.

The high-voltage wire harness terminal welding workstation is equipped with a specially designed welding terminal clamping tool, which can firmly hold the workpiece to be welded, ensuring the stability of the welding process, and ultimately providing customers with efficient, reliable high-voltage wire harness welding solutions.