Ultrasonic Welding Will Become The Standard For Automotive Wiring Harness Welding

Ultrasonic Welding Will Become The Standard For Automotive Wiring Harness Welding

Date:Dec 30, 2020

Ultrasonic welding will become the standard for automotive wiring harness welding


The automotive wiring harness welding market is chaotic. National and industry standards are urgently required: ultrasonic welding will become the automotive wiring harness welding standard


According to statistics released by the Ministry of Public Security of China, as of the first half of 2012, the total number of vehicles in China has “broken 100 million”, reaching 114 million. With the rapid expansion of the scale of my country's automobile industry in recent years, supporting industries related to the automobile industry chain have also obtained market space for simultaneous development. For example, the demand for automobile wiring harnesses has doubled due to the substantial increase in automobile production, and the welding process of automobile wiring harnesses has also increased. Began to be taken seriously.


Ultrasonic welding will become the standard process of automotive wire harness welding


Automotive wiring harnesses are called "vessels" of automobiles, and are usually considered to be the central nervous system of a car, which connects the on-board computer with various related functions on the vehicle. The electronic technology content and quantity of automobile wiring harness in the car has gradually become an important index for evaluating automobile performance.


It is understood that the current automotive wire harness welding production process mainly includes two types: crimping and ultrasonic welding: crimping is the use of terminals to press multiple wires together to form a joint; ultrasonic welding uses the physical effect of ultrasonic vibration to combine the wires. The application of ultrasonic in the production of automotive wiring harness welding first became popular in Europe and America, mainly due to the development of foreign ultrasonic metal welding technology. Compared with the two, the crimping production speed is fast, the equipment is simple, and the cost is low, but there is a risk of metal stamping rebound, and there is a risk of oxidation and rust under severe working conditions, all of which can lead to poor contact. Although the initial investment of ultrasonic welding equipment is relatively high, these risks of crimping do not exist in ultrasonic welding, and the resistance of the wire harness welded by ultrasonic is extremely low, which is basically close to zero.


In addition, in order to meet the technical requirements of automotive wiring harness production, the ultrasonic welding products have obvious technical characteristics: ①The ultrasonic generators are all frequency automatic tracking (no frequency adjustment knob); ②Line width adjustments are all digital settings; ③Multiple parameters Digital setting, storage and recall functions (generally more than dozens); ④There is welding quality control software.


Industry experts said that ultrasonic welding will become the mainstream process of automotive wiring harness welding in the future by virtue of its excellent production efficiency and product performance.


The domestic automotive wiring harness welding market is chaotic, and it is difficult to hide the development dilemma


It is understood that the domestic automotive wiring harness welding market has always been dominated by foreign brands. Domestic auto parts manufacturers mostly rely on foreign ultrasonic wiring harness welding technology, such as TELSONIC in Switzerland, SCHUNK in Germany, AMTECH and SONICS in the United States, and TECHSONIC in South Korea. By means of equipment exports or technical agents of domestic companies, the domestic automotive wiring harness welding market is almost monopolized by foreign brands. In recent years, with the rise of domestic independent brands such as the professional manufacturer of Foshan Chuxin Electromechanical Ultrasonic Metal Welding Equipment, this market pattern has changed. Domestic ultrasonic wire harness welding brands can compete with foreign brands.


The reporter learned from various sources that the quality of ultrasonic automotive wiring harness welding products in the whole country is still uneven, and there are even many fake and shoddy products on the market. Some manufacturers use the existing ultrasonic plastic welding technology circuits and transducers to make ultrasonic metal welding equipment, which cannot meet the technical requirements for mass production of automobile wiring harnesses.


In this regard, the relevant person in charge of Chuxin Electromechanical Company pointed out in an interview with reporters that the development of domestic automotive wiring harness welding is mainly hindered by three aspects: one is the lack of truly professional automotive wiring harness welding manufacturers in China, and the technology has always been limited to foreign countries; Automobile manufacturers and parts suppliers don’t know much about domestic ultrasonic wiring harness welding technology and manufacturers, and there is a distrust mentality; third, the domestic automobile consumer market has always been dominated by Japanese and German cars, but Japan also lacks ultrasonic wiring harness welding. Therefore, the technology has not been used in the welding of vehicle wiring harnesses, and the corresponding domestic manufacturers lack understanding of this.


Industry insiders: optimistic about the prospects of ultrasonic wire harness welding and call for relevant standards to be introduced as soon as possible


Experts pointed out that the analysis of the quality of automotive wiring harness welding products is mainly reflected in two aspects: inspection standards and analysis on welding equipment.


"At present, the country has not issued relevant standards for ultrasonic wire harness welding. "IPC/WHMA-A-620A (Requirements and Acceptance of Cables and Wire Harness Components)" is the standard information we can find about ultrasonic welding wire harnesses, but The standard is only a non-specific quantitative standard constraint such as appearance. The main content of the IPC standard: ①The width-to-thickness ratio of ultrasonic welding is between 1:1 and 2:1; ②The wire must not show any discoloration; ③In The contours of the strands can be identified on the pressurized surface, but there are no loose strands." Chuxin Electromechanical Co., Ltd. Chief Technical Engineer told reporters: "Currently, domestic companies develop their own corporate standards to test products. There are two main evaluation parameters. :①Tensile parameters;②Contact resistance."


It is precisely because of the lack of unified relevant standards and supervision that there are many irregularities and unfair competition in the domestic ultrasonic wire harness welding market, which limits and hinders the healthy and orderly development of the industry to a certain extent. In the interview, many people in the industry agreed that ultrasonic welding, as the mainstream process of automotive wiring harness welding in the future, has a huge market potential. It is hoped that the country and industry associations can issue relevant specifications for ultrasonic wiring harness welding as soon as possible.


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