Ultrasonic Welder

Product Specification

Product Parameters

Product Introduction

The HF-WX-20DZ Ultrasonic Welder is designed for metal welding of large cross-section wire harnesses, copper wires, conductive terminals, copper busbar connectors, and new energy electrical connection parts. It is suitable for production applications that require low heat input, stable electrical conductivity, and consistent welding quality.

In new energy vehicles, high-voltage wire harnesses, battery packs, energy storage modules, charging equipment, and industrial electrical connectors, wire harness terminal welding must provide more than a firm joint. Customers also need stable conductivity, reliable tensile strength, proper terminal forming, and long-term performance under current load.

The HF-WX-20DZ uses ultrasonic metal welding technology. High-frequency mechanical vibration and pressure are applied to join the wire harness and terminal with relatively low heat input. For 35–90mm² wire harness terminal products, this machine is suitable for production lines that require stable joint strength, electrical performance, and appearance consistency.

What Problems Is This Machine Designed to Solve?

Unstable Welding of Large Cross-Section Wire Harnesses

For 35–90mm² wire harnesses, the conductor area is larger and the number of copper strands is higher. If the welding energy is not transferred properly, the joint may show insufficient internal bonding, loose wire ends, or unstable tensile strength. The HF-WX-20DZ is suitable for large cross-section wire harness terminal welding and helps achieve more stable weld formation.

Overheating After Terminal Connection

Wire harness terminals are used for current transmission. If the contact area is unstable, the connection may develop high local temperature, increased contact resistance, or poor long-term reliability during operation. Ultrasonic welding helps form a stable metal bonding surface between the wire harness and terminal, improving electrical connection quality.

Heat-Affected and Oxidation Problems

Ultrasonic metal welding does not rely on large-area melting, so the heat input is relatively low. For copper wires, copper terminals, coated terminals, or components with appearance requirements, it helps reduce oxidation, blackening, deformation, and material damage caused by overheating.

Quality Variation in Batch Production

Wire harness terminal products are usually produced in large quantities. By setting welding energy, pressure, time, amplitude, and other parameters, the machine helps reduce quality variation caused by manual operation and supports a more stable production process.

Key Product Features

Suitable for 35–90mm² Large Cross-Section Wire Harnesses

The HF-WX-20DZ covers a welding range of 35–90mm², making it suitable for high-voltage wire harnesses, high-current cables, copper wire terminals, and new energy electrical connectors. Compared with machines for smaller wire sizes, this model focuses more on compaction, weld formation, and joint stability for large cross-section conductors.

9KW / 12KW Power Options for Higher Energy Demand

Large cross-section wire harness welding requires stronger energy output. The HF-WX-20DZ is available with 9KW / 12KW power options, which can be selected according to wire size, terminal structure, weld area, strength requirements, and production needs.

Low Heat Input to Reduce Material Damage

Ultrasonic welding removes surface oxides through mechanical vibration and forms the joint under pressure. The process usually does not require solder, flux, or filler material. This makes it suitable for products with requirements for conductivity, surface cleanliness, and terminal appearance.

Tight Bonding for High-Current Applications

The welding quality of wire harness terminals directly affects electrical stability. The HF-WX-20DZ is suitable for new energy vehicles, battery packs, energy storage systems, and high-voltage electrical connections, helping reduce poor contact, overheating, and unstable tensile strength.

Typical Applications

New Energy Vehicle High-Voltage Wire Harnesses

Suitable for high-voltage wire harnesses, power battery cables, motor drive cables, and electrical control system connections in new energy vehicles. For terminals carrying high current, welding quality directly affects electrical system stability.

Energy Storage System Connections

Used for energy storage battery modules, internal cabinet connection cables, current-carrying connectors, and related electrical connection parts. The machine is suitable for products that require stable conductivity, strong bonding, and consistent batch quality.

Battery Packs and Electrical Terminals

Suitable for copper wire harnesses, copper terminals, conductive connection pieces, and high-current terminal assemblies in battery packs. Ultrasonic welding helps reduce the risk of weak bonding, looseness, and local overheating.

Charging Piles and High-Voltage Distribution Equipment

Suitable for large cross-section wire harness terminal welding in charging equipment, high-voltage distribution boxes, connectors, and industrial electrical assemblies. Stable welding quality helps improve reliability for long-term current-carrying connections.

Industrial Wire Harnesses and Electrical Connectors

Used for large-size copper wire harness terminals in construction machinery, industrial equipment, power control cabinets, and automation equipment. It is suitable for connection applications with high requirements for strength and conductivity.

Product Advantages

Reduces the Need for Solder and Auxiliary Materials

Ultrasonic metal welding usually does not require solder, flux, or additional filler materials. This reduces material consumption and avoids flux residue that could affect terminal cleanliness or electrical performance.

Helps Control Terminal Appearance and Compaction

After welding large cross-section wire harnesses, customers often check whether the terminal is compacted evenly, whether wire strands are loose, and whether the weld surface is excessively blackened or deformed. With suitable welding horns, fixtures, and parameter matching, the machine helps improve terminal forming consistency.

Reduces Operator-Related Variation

When welding quality depends heavily on manual judgment, different operators or shifts may produce different results. Parameter control and dedicated fixtures help standardize the wire harness terminal welding process.

Suitable from Sample Verification to Mass Production

For new projects, customers can first provide samples, drawings, and testing requirements. Sample welding can be used to verify tensile strength, electrical performance, appearance, and terminal forming quality before confirming the final equipment configuration.

FAQ

Q1. What products is the HF-WX-20DZ mainly suitable for?

A: It is mainly suitable for welding 35–90mm² large cross-section wire harnesses, copper wires, conductive terminals, high-voltage wire harness connectors, new energy vehicle wire harnesses, and energy storage system cables.

Q2. Is this machine suitable for new energy vehicle high-voltage wire harnesses?

A: It can be evaluated for this application. New energy vehicle high-voltage wire harnesses usually require stable tensile strength, electrical conductivity, and long-term reliability. Wire size, terminal drawings, and testing standards should be provided before confirming the configuration.

Q3. Does ultrasonic wire harness terminal welding require solder or flux?

A: Usually not. Ultrasonic metal welding uses high-frequency mechanical vibration and pressure to form the joint, reducing the need for solder, flux, or filler materials.

Q4. How can electrical performance after welding be confirmed?

A: Electrical performance can be confirmed through contact resistance testing, temperature-rise testing, current-carrying tests, or customer-specified electrical tests. Sample welding is recommended before finalizing machine parameters.

Q5. Can one machine handle different terminal sizes?

A: If terminal size and weld area are similar, different products may be compatible by changing fixtures or welding horns. If the size difference is large, tooling and equipment configuration should be evaluated separately.

Inquiry Guidance

If your product involves 35–90mm² large cross-section wire harnesses, copper wire terminals, new energy vehicle high-voltage cables, energy storage connection cables, or high-current conductive terminals, the HF-WX-20DZ Ultrasonic Wire Harness Terminal Welding Machine can be considered as a key option.

You can provide wire specifications, terminal drawings, weld area, tensile strength requirements, electrical testing requirements, and production capacity targets. Haifei can evaluate your actual product, arrange sample welding, verify the process, and recommend an ultrasonic wire harness terminal welding solution suitable for mass production.