WC-U20 Ultrasonic wire harness welding machine

The WC-U20 ultrasonic welding machine welds 0.5-20mm² wire harnesses at 20kHz/3000W, ensuring high-efficiency, low-cost, eco-friendly welding for automotive and similar fields.
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Description

Function

      Welding Operation Functions
  • Welding Frequency Setting: The welding frequency can be set at 20kHz. Through high – frequency vibration, it enables molecular – level welding, which is suitable for welding automotive wire harnesses, single – strand wire harnesses, and large – square – millimeter wire harness terminals.
  • Welding Power Output: With a 3000W welding power, it can provide sufficient energy for various wires with a wire size range of 0.5 – 20mm², meeting the welding requirements of wires with different thicknesses.
  • Multi – mode Welding: It supports three welding modes: energy – based, time – based, and amplitude – based, and the parameters are continuously adjustable. The energy mode precisely controls the total energy input; the time mode strictly controls the welding duration; the amplitude mode adjusts the vibration intensity according to material characteristics.
      Process Control Functions
  • Parameter Limit Setting: The upper and lower limits of time, power, and energy can be set. When the actual parameters exceed the range, it will trigger an alarm or stop the machine, ensuring the stability of the production process.
  • Automatic Frequency Adjustment: It can automatically detect and correct frequency drift in real – time. The built – in memory function can store the optimal frequency settings for different products, facilitating the switch between production runs.
  • Amplitude Adjustment: The full amplitude can be adjusted freely within the range of 0 – 100%. Combined with the constant power output, it ensures that the welding strength is consistent for different workpieces.
     Equipment Operation Functions
  • Soft Start of Power Supply: The welding power supply adopts a soft start (slow ramp – up) design, gradually increasing the power, reducing the mechanical stress on the equipment, and minimizing the risk of arcing and splashing.
  • Power Voltage Adaptability: It is compatible with a 220VAC, 50/60Hz power supply, suitable for different regional power supply standards.
  • Air Pressure Adjustment: The operating air pressure range is 0.5 – 0.7Mpa. The clamping force of the fixture can be adjusted as needed, adapting to workpieces of different sizes.

 

Features

  • High – performance Welding: The combination of 20kHz high – frequency welding and 3000W high power enables it to weld various materials and specifications of wires, with high welding quality and reliable strength.
  • Flexible Adaptability: Multiple welding modes and a wide range of adjustable parameters can quickly adapt to the welding process requirements of different products, enhancing production flexibility.
  • Intelligent and Stable: The automatic frequency adjustment and parameter limit functions ensure the stability of the welding process, reducing manual intervention and lowering the defective product rate.
  • Safe and Reliable: It integrates multiple protection mechanisms such as overload protection, over – temperature protection, and over – current protection. Combined with the soft start of the power supply, it prolongs the service life of the equipment and ensures production safety.
  • Convenient and Practical: With a weight of only 40KG, it is easy to install and move. The modular design supports function expansion, adapting to different production scenarios and future upgrade requirements.

Technical Data

Model WC-U20
Welding capacity 20 kHz
Wire size range 0.5-20mm2
Frequency 20K
Power Supply:220VAC,50/60Hz 220VAC,50/60Hz
Power 3000W
Weight 30kg + 10kgs

Additional information

Description

1. Automotive Manufacturing and Parts Production

Automotive Vehicle Wiring Harness Assembly

Automobiles are equipped with numerous complex wiring harnesses connecting various electronic components and systems, such as engine control systems, in-vehicle entertainment systems, and airbag systems. The 20kHz welding frequency and 3000W welding power of the WC-U20 enable reliable welding of wires with diameters ranging from 0.5 to 20mm², meeting the needs of welding different wire gauges in automotive harnesses. Its multiple welding modes (energy, time, amplitude) can be precisely adjusted according to different harness materials and structures, ensuring stable welding quality and avoiding electrical failures caused by poor welding, thus improving the safety and reliability of the entire vehicle.

Automotive Parts Manufacturing

In the production of automotive parts such as electric seat adjustment systems, window lifting systems, and rearview mirror adjustment systems, the WC-U20 plays a critical role in wiring harness welding. The harnesses for these parts typically require high precision and stability. The welder’s full amplitude adjustment (0-100%) and real-time automatic frequency adjustment function adapt to the welding requirements of different part harnesses, ensuring consistent welding strength and improving the quality and consistency of parts production. Additionally, its multiple protection mechanisms (overload, over-temperature, over-current protection) ensure stable equipment operation during continuous production, reducing the risk of production interruptions due to equipment failures.

2. Electronic and Electrical Equipment Manufacturing

Consumer Electronics

In the production of consumer electronics such as mobile phones, laptops, and tablets, the welding quality of internal wiring harnesses directly affects product performance and service life. The WC-U20 can weld fine single-strand harnesses, and its adjustable welding parameters (such as setting upper and lower limits for time, power, and energy) precisely control the welding process, avoiding damage to electronic components caused by excessive welding energy and ensuring reliable internal circuit connections in electronic products. Meanwhile, the soft start function reduces current surges during welding, minimizing impacts on sensitive electronic components, making it suitable for manufacturing consumer electronics with extremely high welding process requirements.

Household Appliances

For household appliances such as refrigerators, air conditioners, and washing machines, the welding of internal motor connection harnesses and control panel connection harnesses requires reliable processes. The WC-U20’s wide wire diameter welding capability (0.5-20mm²) meets the needs of welding different specifications of wires in household appliances. Its stable welding quality and scalability adapt to the production of different models and specifications of appliances. By setting appropriate welding parameters, it ensures that the welded harnesses maintain good electrical performance in complex environments such as high temperatures and humidity, improving the product quality and stability of household appliances.

3. Aerospace and Military Industries

Aerospace Equipment

Aerospace equipment has extremely high requirements for the reliability and stability of circuit connections, as any defect in a welding point can lead to severe consequences. The high-performance welding system of the WC-U20 can weld special material wires (such as high-temperature-resistant and high-strength alloy wires) used in aerospace equipment. Its precise parameter control and stable welding performance ensure that welding points meet aerospace standards in strength and electrical properties. Additionally, the welder’s modular design and expandable process control functions facilitate integration with other equipment on aerospace production lines, enabling automated welding production and improving production efficiency and welding quality consistency.

Military Equipment

In military equipment manufacturing, such as radar systems, communication devices, and missile control systems, the welding quality of internal wiring harnesses is critical to the equipment’s combat performance and reliability. The WC-U20’s multiple protection mechanisms (overload, over-temperature, over-current protection) ensure stable equipment operation in complex military production environments, reducing production delays caused by equipment failures. Its flexible welding modes and adjustable parameters meet the welding requirements of different types of harnesses in military equipment, ensuring that the welded harnesses can operate normally in harsh environments (such as high temperatures, high pressure, and strong electromagnetic interference), enhancing the overall performance and reliability of military equipment.

4. New Energy Sector

Electric Vehicles

With the rapid development of electric vehicles, the welding quality of battery pack connection harnesses and motor controller harnesses has become a key factor affecting vehicle performance and safety. The WC-U20’s high-power welding capability (3000W) enables reliable welding of large-square harnesses (such as high-voltage connection harnesses in battery packs) in electric vehicles, ensuring stable transmission of high currents. Its intelligent and stable welding process control (such as automatic frequency adjustment and parameter limit setting) effectively avoids safety hazards like battery pack short circuits and overheating caused by poor welding, improving the safety and reliability of electric vehicles.

Solar and Wind Power Generation Equipment

In the production of solar photovoltaic panels and wind turbines, internal circuit connections require efficient and reliable welding processes. The WC-U20 can weld the battery cell connection harnesses in solar photovoltaic panels and the control circuit harnesses inside wind turbines. Its wide range of wire diameter welding capabilities and flexible welding modes adapt to the welding needs of different specifications and types of wires, ensuring stable internal circuit connections in power generation equipment and improving power generation efficiency and equipment service life.

 

If you need to supplement content for these application areas or delve deeper into application details in a specific field, feel free to let me know.

Technical Data

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