Ultrasonic Wire Harness Welder EVC-IV
Scope of Application:
Wire Harness Welding (10mm²-150mm²)
Key Technical Highlights:
Key Technical Highlights:
- Real-time welding height monitoring with micron-level precision, ensuring exceptional dimensional accuracy for every weld joint.
- Dynamic pressure tracking with closed-loop control, triggering instant alarms for any fluctuations to prevent process anomalies.
- Automatic defect classification powered by intelligent diagnostic algorithms, facilitating rapid root cause analysis and predictive maintenance.
- Extensive data logging for critical welding parameters (including power, time, energy, and post-weld height), supporting seamless MES integration for full lifecycle traceability from production to delivery.
High-Power Ultrasonic Welding System for Large Cross-Section Wires
This equipment is purpose-built for heavy-duty ultrasonic welding of large cross-section wires. Featuring a robust high-power ultrasonic drive architecture, it ensures superior metal splicing quality for copper and aluminum conductors ranging from 10mm² to 150mm².
The system is deeply optimized to meet the extreme energy demands of thick wire welding. Through multi-stage closed-loop amplitude control and adaptive energy management, it automatically matches the optimal welding recipes when switching between different wire specifications. This guarantees consistent weld tensile strength and reliable solid-state bonding across the entire range. Whether handling standard 10mm² wire harnesses or extra-large 150mm² battery cables, the equipment delivers stable metallurgical bonding quality, meeting the rigorous requirements for high-voltage electrical connections in New Energy Vehicles (NEVs) and Energy Storage Systems (ESS).
Equipment Functions and Features:
- Industrial HMI powered by Windows 10, offering a graphical process visualization for intuitive operation.
- Secure user access levels with password protection, ensuring full parameter traceability for strict quality compliance.
- Integrated industrial QR and barcode scanning to streamline product identification and inventory management.
- Flexible processing modes supporting synchronous inline welding and complex multi-step sequence welding.
- Seamless MES (Manufacturing Execution System) integration with remote parameter control and bi-directional data exchange.
- Robust fault diagnosis and error correction capabilities to maximize uptime in high-volume production.
- KSK modular architecture enabling automatic BOM recognition, which triggers recipe auto-loading and parameter self-configuration for rapid changeovers.
- Adaptive height compensation algorithms that automatically adjust for ultrasonic horn wear, guaranteeing consistent weld nugget quality.
- Equipped with a premium imported ultrasonic generator and transducer, delivering high-amplitude stability and exceptional MTBF (Mean Time Between Failures).
- Flexible OEM/ODM software customization available to meet specific turnkey project requirements.
| Machine model | EVC-IV |
|---|---|
| MP Capacity(area) | 10-150mm² |
| Overall imensions (L*W*H) | 1200*900*1400mm |
| Weight | 100kg |
| Working voltage | 380V AC |
| Max.power | 12KW |
| Working air pressure | 0.1-0.6MPa |
| Air filtration accuracy | 5μm |
| Working temperature | -20℃~40℃ |
| Working frequency | 20KHZ |
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.
