Wire Processing and Electrical Installation Equipment

Ultrasonic Wire Harness Welding Machine (3000W / 0.35–20 mm²) EW-6010

Price of the selected optionon request
Delivery options

Description

Feature

● Solid-State Ultrasonic Joining (20 kHz / 3000W): Creates zero-resistance, gas-tight molecular bonds between copper-to-copper, aluminum-to-aluminum, or dissimilar copper-to-aluminum conductors.

● Broad Splicing Range (0.35–20 mm²): Versatile dual-range capacity accommodates fine signal leads (0.35–3 mm²) up to heavy automotive power splices (3–20 mm²).

● Smart Factory & MES Connectivity: Connects seamlessly with factory MES networks for real-time welding data tracking, automated job dispatching, and complete process traceability.

● In-Line Quality Monitoring System: Continuously tracks weld energy, time, and collapse height during every cycle to guarantee joint strength and detect out-of-tolerance wires.

● Eliminates Crimp Sleeves & Solder Flux: Saves material costs and reduces harness bundle weight by welding bare conductors directly, preventing thermal degradation and corrosion.

● Automatic Adjustment & Overload Protection: Microprocessor-controlled automatic parameter tuning shortens setup times, while overload protection guards piezoelectric transducers and welding horns.

Application Range

● Automotive Wire Harness Splicing: In-line wire-to-wire splicing and wire end knotting for door looms, dashboard harnesses, and engine bays.

● EV & New Energy Vehicle Cabling: High-reliability copper and aluminum conductor welding for battery packs, charging ports, and power distribution units.

● Relay & Sensor Assemblies: Precise, flame-free micro-welding for relay leads, fuse blocks, and multi-pin sensor junctions.

● Industrial & Home Appliance Wiring: Solderless, flux-free wire jointing for home appliances, power tools, and industrial machinery controls.

Specifications

Model
EW-6010
Welding Capacity Range
0.35 – 3.0 mm² / 3.0 – 20.0 mm²
Ultrasonic Frequency
20 kHz
Compatible Wire Materials
Copper, Aluminum, or Copper-to-Aluminum Dissimilar Metals
Welding Process Applications
Wire-to-wire splicing, wire end knotting, relay leads, battery leads
Control System & Connectivity
Industrial Control System with MES Connection Capability
Quality Control Features
In-line weld quality monitoring, automatic parameter tuning
Power
3000W
Voltage
AC110V/220V/50HZ/60HZ
Air pressure
0.5-0.7Mpa
System
Overload protection safety system
Application for Ultrasonic Wire Harness Welding Machine (3000W / 0.35–20 mm²) EW-6010