Ultrasonic Wire Splicer



Ultrasonic Welding for Wire Splicing

Ultrasonic metal welding is a crucial joining technology used in the creation of wire harnesses for many industries, but primarily automotive. The process involves joining multiple wires with each other or joining wires with terminals or conductive contacts. Compared with more traditional welding methods like crimping or resistance welding, ultrasonic welding offers several advantages. These include the higher quality of weld joints, better process control and low energy consumption. The US-3620WN2 ultrasonic wire splicer creates the highest quality welds; a strong, surface molecular, solid-state bond that is clean and has high electrical conductivity.

Wire harnesses have a wide variety of applications. For example they are used in automobiles, trains, aircraft, factory automation equipment, home appliances, office automation equipment, medical equipment and communications equipment. The market share for the automotive wire harnesses is amongst the largest and has a major impact on the global economy. The global market for wire harnesses for the automotive industry is about $ 4.5 billion in 2019. With the amount of electrical components mounted on automobiles increasing, the amount of wire harness needed to connect these components also increases.

16mm² Copper Wire Splicing

Ultrasonic Welding Advantages for Wire Splicing

The US-3620WN2 ultrasonic wire splicer machine offers an entry level welding experience for all types of customers. It is a user-friendly and low-maintenance ultrasonic welding solution for many markets with minimal tooling costs. The machine’s weld capabilities cover a large range of cross-section sizes running from .5mm2 – 34mm2. In addition, it provides numerous benefits over traditional welding methods such as, a pure metallurgical bond for many non-ferrous materials, ability to weld dissimilar materials, fast cycle time, and consistent weld quality. This ultrasonic wire splicer is a one step splice or crimp machine for the joining of non-ferrous metals. No heat is applied and there are no consumables or connectors needed.

Features and Benefits of Ultrasonic Welding for Wire Splicing

  • Simple one-step calibration using 3mm pin gauge
  • Ability to weld cross section area ranging from .5mm2 – 34mm2
  • Precise measurement of pre-weld and post-weld height
  • Operates at 20 times less energy than resistance welding
  • No need for outside consumables used in current crimping and soldering methods 
  • Tooling can last over a million cycles with small wire splices 
4mm² Copper Ultrasonic Wire Splicing

For more technical information, please download our brochure.

Ultrasonic Wire Splicer Samples