Feature
● Copper-to-Terminal and Aluminum-to-Terminal Welding in One Machine
The EW-6160 welds copper wire to silver-plated copper, nickel-plated copper, or bare copper terminals, and separately welds aluminum wire to silver-plated copper, silver-plated aluminum, or bare copper terminals — covering both same-metal and dissimilar-metal (copper-aluminum) terminations within its 15–70mm² range. This dual-material capability is particularly relevant for EV high-voltage harness design, where aluminum conductors are increasingly specified for weight reduction but require aluminum-compatible terminal welding to avoid the galvanic corrosion risk of improperly joined copper-aluminum interfaces.
● 180° Welding Configuration for Heavy Cable Terminal Joints
The machine performs 180° welding — the cable and terminal are presented to the welding horn at a straight, in-line orientation rather than an angled or perpendicular approach. This configuration is suited to heavy-gauge cable terminal applications where the terminal extends as a straight continuation of the cable axis, common in power distribution lugs and battery terminal connections in the 15–70mm² range.
● First-Five-Piece Self-Learning Quality Monitoring
Rather than relying on fixed, manually-set tolerance thresholds, the EW-6160's self-inspection function uses the first five welds of a production batch to automatically establish a quality baseline across weld height, output power, weld time, and weld energy. Every subsequent weld is compared against this learned baseline; a weld falling outside the established range triggers an abnormal alarm and automatic shutdown before further defective parts are produced. This adaptive approach accounts for normal cycle-to-cycle variation specific to each wire/terminal combination, rather than applying a single generic tolerance across all production setups.
● Two-Hand Start or Scan Gun Trigger — Safety and Traceability Options
Production cycles are initiated either by two-hand start (requiring both operator hands on dedicated start buttons, preventing hand placement in the welding zone during cycle initiation on heavy cable handling) or by scan gun trigger (scanning a part number or work order barcode to both initiate the cycle and link the weld record to a specific production batch). The scan gun option is the preferred configuration when per-piece traceability is required for automotive or aerospace quality documentation.
● Optional MES Integration for Centralised Production Data
Welding output power, welding stroke, and welding time for each cycle can be streamed to a factory MES system, allowing centralised quality dashboards and OEE tracking across multiple welding stations. MES integration requires a custom docking system to be specified at the time of order — contact Eastontech in advance to confirm protocol compatibility with your existing factory systems.
Application Range
EV high-voltage battery and power cable termination
Electric vehicle battery pack interconnects, motor power feed cables, and DC fast-charging cable terminations in the 15–70mm² range require low-resistance, vibration-resistant joints without the flux contamination risk of soldering near battery chemistry. The EW-6160's solid-state ultrasonic bond and copper/aluminum dual-material capability directly address the increasing use of aluminum conductors in EV high-voltage harness design for weight reduction.
Power distribution and switchgear lug welding
Heavy power cable lugs for distribution panels, transformer connections, and industrial switchgear use 15–70mm² copper or aluminum conductors where ultrasonic welding eliminates the flux residue and cold-joint risk associated with soldering these large terminations, while the 180° welding configuration suits the straight in-line cable-to-lug geometry typical of these applications.
Renewable energy and energy storage cable terminations
Wind turbine generator cables, solar inverter DC bus connections, and battery energy storage system (BESS) interconnects use heavy copper or aluminum conductors requiring reliable, low-resistance terminal welds. The first-five-piece self-learning quality monitoring provides the documented quality assurance increasingly required by renewable energy equipment certification standards.
Railway and industrial heavy power cable welding
Rolling stock traction power cables and industrial motor feed terminations in the 15–70mm² range benefit from the EW-6160's MES integration capability, supporting the production traceability documentation required by railway electrical equipment manufacturers operating under quality management systems.
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Tell us your need by filling out the form below and we will contact you as soon as possible!.input_group label{ line-height:35px;} Interesting Products Name * Company Email * Tel/Mobile * Country Tell us your needs (as specific as possible)
Tell us your need by filling out the form below and we will contact you as soon as possible!.input_group label{ line-height:35px;} Interesting Products Name * Company Email * Tel/Mobile * Country Tell us your needs (as specific as possible)