Electromagnetic Pulse Equipment EMPT-MINI
An industrial-grade Electromagnetic Pulse Crimping (EMPT) system engineered for high-voltage EV wire harnesses and battery pack manufacturing.
Heavy-Duty Cable Range: Designed for 35 mm² to 150 mm² and above automotive cables.
Dissimilar Metal Joining: Perfect metallurgical cold welding for Copper to Aluminum (Cu/Al).
Superior Joint Performance: Delivers ultra-low impedance and 360° gas-tight hermetic sealing.
Zero Thermal Distortion: Microsecond solid-state process ensures zero heat-affected zone.
Target Applications: Premium solution for Tier 1 suppliers in EV powertrain and ESS systems.
| Machine model | EMPT-MINI |
|---|---|
| MP Capacity(area) | 35~150mm² |
| Overall imensions (L*W*H) | 1300*1200*2150mm |
| Weight | 500kg |
| Working voltage | ≤220V AC |
| Max.energy | 25KJ |
| Working temperature | 0℃~40℃ |
Revolutionary Cold-Welding Technology for High-Current Connectivity
The High-Performance Electromagnetic Pulse Crimping Equipment introduces a solid-state, non-contact welding solution tailored for the demanding specifications of the electric vehicle (EV) and energy storage industries. By unleashing an intense, microsecond-range electromagnetic field, the system drives the outer terminal sleeve into high-velocity impact with the inner cable conductor.
This hyper-velocity collision strips surface oxides and forces an atomic-level metallurgical bond (cold weld) between dissimilar or similar metals, such as Copper to Aluminum and Copper to Copper .
Key Technical Advantages
Atomic Metallurgical Bonding (Zero Contact Resistance) Unlike mechanical crimping that relies on friction, EMPC creates a true continuous metallurgical joint. This ensures near-zero contact resistance, preventing temperature spikes during high-current operations.
360° Symmetrical Compression Elimilates the flash, burrs, and uneven stress distribution typical of conventional hex or indent die crimping. The resultant joint maintains perfect cylindrical symmetry and uniform density.
Gas-Tight & Liquid-Tight Sealing (IP67+ Pass) The extreme radial compression creates a hermetic seal, completely blocking moisture and air ingress, which effectively eradicates electrochemical corrosion in copper-aluminum junctions.
Zero Heat-Affected Zone (HAZ) The entire discharge process finishes within microseconds. Because no external heat is applied, cable insulation, shielding wraps, and adjacent temperature-sensitive components remain completely undamaged.
Zero Tooling Wear & High Consistency Operating as a non-contact process with no heavy mechanical dies, the discharge coils experience virtually no mechanical wear, guaranteeing identical joint quality across millions of cycles.
Typical Application Fields
Automotive EV High-Voltage Wire Harnesses Seamless crimping of thick-wall tubular terminals (Lugs) onto high-voltage shielding cables.
Energy Storage Systems (ESS) & Battery Packs High-conductivity welding of battery busbars, heavy-duty power cables, and multi-layer tab terminations.
High-Voltage Coaxial Cables High-precision electromagnetic shielding net crimping for telecommunications and EV high-frequency power transfer.
Dissimilar Metal Transitions Reliable mass production of aluminum wiring transitions to copper connectors without brittle intermetallic compound (IMC) formation.
FAQ
Can you provide remote technical support?
Yes, we offer 24/7 remote support.
Can you guarantee consistent welding quality?
This equipment/process can guarantee that the welding quality meets the requirements of Cpk ≥ 1.67 and Cmk ≥ 1.67.
Do you provide on-site installation and training?
Yes. Our service engineer will travel with the equipment to your site and carry out on-site installation and training.
Is your equipment CE certified?
The ultrasonic metal welding equipment comes with CE certification and UL certification.
What is the lead time for the equipment?
For standard equipment, the lead time is between 14 and 45 working days. For non-standard or customized equipment, the lead time will be determined based on mutual agreement between both parties.
What is the warranty period for your ultrasonic metal welding equipment?
Our equipment comes with a standard 1-year warranty.
