Ultrasonic Wire Welding Machine for Wiring Harness – 20 kHz 4200W

Wiring harnesses consist of multiple wires bundled together to transmit power and signals between components. The quality of each joint directly impacts system performance and reliability.

The altrAsonix ultrasonic welding system provides a fast, clean, and efficient solution for joining these wires. By combining high-frequency vibration with controlled pressure, it creates strong metallurgical bonds that ensure long-term electrical stability and mechanical strength.

Unlike traditional methods, ultrasonic welding does not melt the material, preserving the original structure and conductivity of the wires.

Working Principle

Ultrasonic welding converts electrical energy into high-frequency mechanical vibrations. These vibrations create friction between metal surfaces, enabling bonding at a molecular level.

Step-by-step process:

• Wires are placed on the welding anvil
• The ultrasonic horn applies controlled pressure
• Vibrations at 20 kHz break oxide layers and contaminants
• Clean metal surfaces come into contact
• A solid-state bond is formed under pressure

This process results in a strong, low-resistance, and highly reliable electrical connection.

Types of Wire Welds Supported

• Wire-to-wire welding
• Multi-strand wire welding
• Wire-to-terminal welding
• Copper-to-copper welding
• Aluminium-to-aluminium welding
• Copper-to-aluminium welding
• Parallel and cross-wire joints

Material Compatibility

The machine supports a wide range of conductive materials, including:

• Copper wires
• Aluminium wires
• Tinned wires
• Multi-strand cables
• Dissimilar metal combinations (Cu-Al)
• Electrical conductors used in harness systems

Key Features

• Advanced 20 kHz ultrasonic welding technology
• 4200W power for medium to heavy-duty applications
• Solder-free and flux-free process
• Strong metallurgical bonding with low resistance
• Fast welding cycle for high productivity
• Digital control system for precise parameter adjustment
• Stable and repeatable weld quality
• Compact and rugged industrial design
• Low maintenance requirements

Technical Specifications

Applications

• Automotive wiring harness manufacturing
• Electronics and PCB wiring systems
• Industrial automation and control panels
• Home appliance wiring
• Electrical cable assembly
• Power distribution wiring systems
• Industrial machinery and equipment

Advantages of Ultrasonic Welding

1. High Electrical Conductivity
Produces extremely low-resistance joints, improving efficiency.

2. Strong Mechanical Strength
Creates durable connections resistant to vibration and stress.

3. No Consumables Required
Eliminates solder, flux, and filler materials.

4. Minimal Heat Generation
Protects insulation and sensitive components.

5. Fast Production Speed
Reduces cycle time and increases output.

6. Consistent Quality
Ensures repeatable weld results across production batches.

7. Environment-Friendly Process
No fumes, chemicals, or waste materials involved.

FAQ

1. What is an ultrasonic wire welding machine?
It is a machine that joins wires using ultrasonic vibrations and pressure without melting the metals.

2. Which materials can be welded?
Copper, aluminium, tinned wires, and mixed metal combinations can be welded.

3. What wire sizes are supported?
Typically from 0.5 sqmm to 20 sqmm, depending on the model.

4. Why is ultrasonic welding preferred for wiring harnesses?
It provides strong, low-resistance connections with minimal heat, ensuring reliability and long life.

5. Does the process damage insulation?
No, the process generates very little heat and protects surrounding insulation.

6. What welding modes are available?
Time Mode and Energy Mode for precise control of welding parameters.

7. Are different power models available?
Yes, machines from 3000W to 6000W are available for different industrial requirements.