Feature
● Copper and Aluminum Wire-to-Terminal Bonding — No Solder or Flux
The EW-6080 bonds wire conductors to terminal lugs by converting 20KHz electrical energy into localised mechanical vibration at the wire-terminal interface, generating friction heat sufficient to fuse the contact surfaces without reaching full melt temperature. The resulting solid-state bond has near-zero contact resistance and no flux residue — eliminating the corrosion risk and insulation contamination that soldered terminal connections can introduce in sealed or enclosed connector environments.
● Three Power Grades for 4–50mm² — Including 380V Heavy Cable
The three-model range covers mid-range power cable (4–16mm², 3,000W, 220V), medium-heavy power feeds (4–25mm², 4,000W, 220V), and heavy cable terminations (6–50mm², 6,500W, 380V). The EW-6080-2's 380V three-phase supply delivers the sustained welding energy required for 50mm² aluminum cable — where the high thermal conductivity of large aluminum conductors demands higher continuous power than single-phase 220V systems can maintain at this cross-section.
● Compatible with Both Copper and Aluminum Conductors and Terminals
The same ultrasonic welding process bonds copper-to-copper, aluminum-to-aluminum, and copper-to-aluminum combinations — accommodating the mixed-material terminal assemblies used in EV battery systems where aluminum conductor cables terminate into copper terminal lugs at busbar connections. No process parameter change or tooling swap is required between conductor material combinations within the same cross-section range.
Application Range
● EV battery cable and high-voltage harness termination
Battery pack interconnect cables and HV harness main conductors in electric vehicles use large cross-section copper and aluminum cables (10–50mm²) terminating into copper or aluminum compression lugs. Ultrasonic welding produces a flux-free, spark-free bond at these cross-sections that meets EV battery system cleanliness requirements where solder flux contamination near battery chemistry is prohibited.
● Power distribution and switchgear cable lug assembly
Main distribution cables (16–50mm²) for MV/LV switchgear, transformer secondary connections, and industrial motor feeds require reliable, low-resistance conductor-to-lug bonds at the cable end preparation stage. The EW-6080-2's 6,500W capacity handles the continuous energy demand of 50mm² cable termination at production rates required for switchgear assembly lines.
● Renewable energy and EV charging infrastructure
Solar PV string cables, wind turbine generator cables, and EV charging station main power feeds use 16–50mm² aluminum or copper conductors where consistent terminal bond quality directly affects system efficiency and long-term connection reliability. The EW-6080 series' three power grades match the cable cross-sections used across the full renewable energy cable range.
● Automotive body and powertrain ground and power connections
Battery ground cables, power distribution box feeds, and starter motor cables in conventional and hybrid vehicles use 16–35mm² copper cables with compressed lug terminations. Ultrasonic welding eliminates the crimping force variation that causes cold crimp failures on these safety-critical connections, producing a dimensionally consistent bond that passes pull-force and resistance testing across the full production batch.
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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)