What problems should be considered in automotive wire harness welding?

 There are many benefits of ultrasonic automotive wiring harness welding, but at the same time, what problems should be considered in ultrasonic automotive wiring harness welding? What are some of them?

The following issues must be considered for ultrasonic automotive wire harness welding:

1. The cable should not be tinned or galvanized, although it can be welded under certain conditions, the effect will be reduced (the same square number of wire diameter, the welding power required is different, the soldering power of the tinned wire is significantly larger, and the tinned copper wire is harder than the copper wire, and it is easier to disconnect). 2. Select the model according to the cable cross-sectional area. Ultrasonic wire harness welding machine NC-X2020E: applicable to welding line cross-sectional area of 0.5-15mm;

Ultrasonic wire harness welding machine technical requirements, according to IPC standards:

a. Standard ultrasonic welding harness, width to thickness ratio between 1:1 and 2:1;

b. Do not discolor the cable.

c. The contour of the strand can be identified on the pressurized surface, but there is no loose strand, in other words, there can be no burrs.

d. After welding, the wiring harness can not be disconnected, so according to the above standards and automotive wiring harness manufacturing multi-specification requirements.

There are the following technical standards for ultrasonic wire harness welding machines:

1. Ultrasonic power is continuously adjustable. Because the ultrasonic energy will be lost in the direction of the wire harness thickness, the thicker the wire junction, the greater the necessary ultrasonic die power. The ultrasonic power is continuously adjustable, and can also prevent discoloration of the cable surface of different areas. In the same machine, when welding 1 mm and 15 mm wire harness, the power can be adjusted to ensure the perfection of wire harness welding.

2. Wire fixture gap ≤ 0.02mm. Ultrasonic welding is high energy density, and large gaps will lead to stuck lines. 3. Quality control software. It is required that the machine can make a quality evaluation of each solder joint: determine what case is bad welding, what case is missing line, etc., and give a warning.