​The Difficulty Of Ultrasonic Wire Harness Welding In New Energy Vehicle Welding

​The Difficulty Of Ultrasonic Wire Harness Welding In New Energy Vehicle Welding

Date:Nov 03, 2020


The difficulty of ultrasonic wire harness welding in new energy vehicle welding


New energy vehicles are a hot spot in recent years and the following years, and their development speed is very fast. Due to the large-scale application of high current and copper and aluminum alloys, ultrasonic technology has become one of the main welding processes. At the same time, the continuous improvement of technical requirements makes the ultrasonic technology will be greatly improved, mainly high power, large area. Currently, there are some difficulties in practical applications


1. Lack of welding standards.


National standards for ultrasonic welding are missing.


At present, automobile wiring harness manufacturers basically follow the German Volkswagen standard or Delphi standard, but these standards do not apply to the large square wiring harness of new energy;


At present, only the uscar 38-1 standard of the United States can be seen, but not in China;


Copper and aluminum welding standards can only refer to corporate standards, such as catl standards. There are many problems in the catl standard. For example, when the thickness of the aluminum plate is too large, the tear residual index may not be reasonable.


2 wires + terminals, the terminals are getting thicker and thicker, and the square number of wire joints is getting larger. Therefore, the problems of large ultrasonic radiation attenuation and large power capacity must be solved.


three. As aluminum bars are getting thicker, it is necessary to solve the problem of aluminum bars sticking to the welding head.


4 The copper rod is getting thicker and thicker, and the problem of fixing the anvil must be solved.


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