Ultrasonic Wire Hardness Welder
An ultrasonic wire harness welder built for new energy vehicle production — welds, crimps and shapes harnesses from 0.35 mm² to 35 mm² at 0.02 mm precision, with automatic amplitude compensation holding every joint consistent.
Harness joints that survive the vehicle
In a new energy vehicle, a harness joint carries high current through years of vibration and thermal cycling. Crimping leaves micro-gaps between strands and lets oxidation build up over time; soldering adds heat and a consumable.
Ultrasonic welding fuses the strands into one solid mass instead. There are no crimp voids, no oxidation between strands, and the measured contact resistance is lower than a crimp — on a joint made in a fraction of a second with nothing consumed.
Six reasons harness lines switch to ultrasonic
0.02 mm welding precision
Welding precision reaches 0.02 mm — tight enough for high-voltage harness work where joint height is specified.
One machine, 0.35–35 mm²
The full cross-section range is covered on a single machine, instead of buying several presses for one line.
Multi-core system chip
A multi-core control chip gives faster system response, so the weld triggers and ends exactly on target.
Automatic amplitude compensation
Amplitude is compensated automatically, holding power output stable and making weld quality repeatable.
Lower resistance than crimping
Fused strands carry current with fewer micro-gaps and far less oxidation between them.
Vibration-proof joints
Solid-state bonds tolerate automotive vibration and thermal cycling better than soldered joints.
Ultrasonic Wire Harness Welder — specification
The figures below come from our standard configuration. Frequency, power and tooling size can be customised on request — send us your harness cross-section, strand count and target cycle time and we confirm the build.
Both single-strand and multi-strand harnesses run on the same machine, and automatic compensation keeps energy delivery steady as the supply voltage varies.
Ultrasonic Wire Harness Welder — specification
| Item | Value |
|---|---|
| Product name | Ultrasonic Wire Harness Welder |
| Application | Wire harness welding, crimping, shaping |
| Cross-section range | 0.35 – 35 mm² |
| Strand type | Single-strand and multi-strand |
| Welding precision | 0.02 mm |
| Control | Multi-core system chip, automatic amplitude compensation |
| Typical use | New energy vehicle (NEV) harness production |
| Consumables | None — no solder, flux or crimp sleeves |
| Customisation | Frequency, power and tooling size on request |
Built for new energy vehicle harness work
EV & NEV Harnesses
High-voltage harness welding for new energy vehicle platforms, where joint resistance and vibration life are both specified.
Terminal Crimping
Ultrasonic crimping of terminals onto multi-strand ends — a solid bond instead of a mechanical crimp.
Single-Strand Welding
Single-conductor splicing with repeatable energy delivery and a clean, oxide-free joint.
Multi-Strand Splicing
Stranded copper fused into one mass — no crimp voids, no oxidation between strands.
Assembled and tuned in our own workshop
Questions buyers ask before ordering
Can you weld our harness samples first?
Yes. Send a length of your harness with the cross-section and strand count and we weld it in our application lab, then return the samples with photos and the recommended parameters.
What cross-sections can one machine cover?
0.35 mm² to 35 mm² on the same machine — the range is wide enough that most lines do not need a second press.
Does it handle both single-strand and multi-strand?
Yes, both. The horn and anvil are selected for the cross-section, and automatic amplitude compensation keeps energy delivery stable across the range.
How does ultrasonic welding compare with crimping?
Fused strands give fewer micro-gaps and lower contact resistance than a crimp, and the joint survives vibration and thermal cycling better. There is also no crimp sleeve to buy or stock.
Other metal welding systems
Send us your harness for a free weld test
Tell us the cross-section, strand count and target cycle time. We weld your samples in our application lab and return the recommended configuration, tooling drawing and parameters — usually within 2–3 working days.
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