Closed-Loop Control
Reel-Feed Terminator

Conduction is a growing concern for many EV manufacturers in today’s competitive landscape. In order for EV’s to function properly, effective low resistance wire bonding is required. Ultrasonic welding is the ideal joining process for joining wires, efficiently producing low-resistance bonds. TECH-SONIC’s patent-pending closed-loop control ultrasonic wiring termination machine, model US-3620MAK-S, provides a new ultrasonic metal welding capability beyond conventional ultrasonic metal welders. It bonds single point ground terminals and can accommodate a variety of terminals by changing terminal nest hardware. It uses a microprocessor-controlled ultrasonic welder and servo-controlled spot welding hardware that can weld multiple wires onto a single terminal and provide a stress-free joint. In compliance with USCAR-38, it has the ability to detect 3% of total CSA.

The US-3620MAK-S wiring termination machine also features industry-leading missing wire and strand detection. A typical pneumatic termination machine can only detect missing wires if they are greater than 5% of the total cross section of wires. The US-3620MAK-S ultrasonic wiring termination machine can detect missing wires less than 3% of the total cross section and can detect the loss of a single 0.35mm² wire, which is commonly retracted from the weld area without the user’s awareness. Many automobile manufacturers require the wire harness producers to detect less than 3% of missing wires and have determined that the limitations of the pneumatic process prevent them from providing consistently acceptable part quality.