Preface

Ultrasonic welding is a popular joining technique used in the manufacture of wiring harnesses. It uses high-frequency vibrations to generate heat and melt materials at the joint interface, fusing them together. Ultrasonic welding offers several benefits over other methods like soldering, crimping and heat staking.

How Ultrasonic Welding Works

Ultrasonic welding uses an ultrasonic welding machine to produce high-frequency vibrations, typically 20,000 cycles per second. These vibrations are transferred to the joint area through a welding tip, called a sonotrode. The vibrations cause the materials to heat and melt at the interface, fusing them together in a process known as intermolecular friction.

The key steps in ultrasonic welding

A. The parts to be joined are held under pressure by the sonotrode.

B. High-frequency vibrations are generated by a piezoelectric transducer in the welding machine.

C. The vibrations are amplified and transferred to the sonotrode.

D. The vibrations cause the materials at the joint interface to heat and melt due to intermolecular friction.

E. The molten materials fuse together and solidify, creating a strong weld.

F. The sonotrode is removed, leaving behind a clean, minimal weld.

Following is operation video of HH-X0 Wire Ultrasonic Welding Machine

https://youtube.com/shorts/4u2luPG0sxY

The main factors that determine weld strength and quality

A. Amplitude (height) of vibrations: Higher amplitude produces more heat and a stronger weld.

B. Frequency of vibrations: Higher frequency also produces more heat and a better weld.

C. Weld time: Longer weld time results in a stronger weld as more heat is generated.

D. Pressure: Higher pressure helps the molten materials fuse together more effectively.

E. Surface area: Larger surface area allows more intermolecular friction and a stronger weld.

F. Material compatibility: Materials must have similar melting points to properly fuse together.

Following is operation video of HH-X0 Wire Ultrasonic Welding Machine

https://youtube.com/shorts/orj6KLl_gGs

Benefits of Ultrasonic Welding for Wiring Harnesses

A. Clean welds: Ultrasonic welding produces minimal splatter or residue. The weld area is clean and aesthetically pleasing.

B. Precise control: The welding parameters can be precisely controlled to produce consistent, high-quality welds.

C. High productivity: Ultrasonic welding is fast, automated, and suitable for high-volume production.

D. Minimal heat: Only the weld area is heated, avoiding damage to temperature-sensitive components.

E. Low porosity: The applied pressure helps produce welds with minimal porosity or voids.

F. Minimal post-weld finishing: Little or no post-weld grinding, sanding or polishing is required.

G. Environmentally friendly: Ultrasonic welding does not require toxic chemicals like solder flux. No fumes are produced.

H. Reduced costs: Ultrasonic welding equipment has a lower capital cost than some other methods. It also reduces waste and rework.

I. Versatility: Ultrasonic welding works with a wide range of materials, including plastics, metals, glass and ceramics.

Following is operation video of HH-X0 Wire Ultrasonic Welding Machine

https://youtube.com/shorts/zAxLBp05e0g

Applications of Ultrasonic Welding in Wiring Harnesses

A. Wire to connector: The wire end is welded inside the connector housing for a secure termination.

B. Connector housing halves: The housing pieces are welded together over the wire termination.

C. Wire splices: Wire ends are welded together to form a splice. Heat-shrink tubing is often applied over the weld.

D. Ground straps: Braided ground straps are welded to components to provide a low-resistance ground path.

E. Fuses and fuse clips: Fuses are welded to fuse clips or holders to complete a circuit.

F. Terminals: Wire ends are welded to spade or ring terminals, which are then secured under bolt heads.

G. Shielding: Wire shielding or braiding is welded to the wire insulation to provide EMI/RFI shielding.

Find HH-X0 Wire Ultrasonic Welding Machine at the follwing link of our website.

HH-X0 Wire Ultrosonic Welding Machine

Summary

Ultrasonic welding is an ideal joining method for wiring harnesses due to its speed, precision, and minimal environmental impact. It produces high-quality, consistent welds between wires, connectors, terminals, shielding and other components. Ultrasonic welding helps improve productivity while reducing costs, making it a very attractive process for high-volume wiring harness manufacturing.