Process Analysis of Wiring Equipment for Automobile Wire Harness

First, the car wiring harness welding: crimping and ultrasonic welding

Automotive wiring harness welding The current production process is mainly crimped and ultrasonic welding two: crimping is the use of terminals will be multi-stranded wire together to form a joint; ultrasonic welding is the use of ultrasonic vibration generated by the physical effects of the thread together. Ultrasonic used in automotive wiring harness welding production, the earliest popular in Europe and the United States, mainly due to the development of foreign ultrasonic welding technology. Comparison of two welding techniques:

(A) crimping

Advantages: production speed; simple equipment.

Disadvantages: metal stamping there is a risk of bounce; bad conditions, there is the risk of oxidation and rust, all risks can lead to poor contact.

(B) ultrasonic welding

Advantages: Super electrical connection characteristics (basic zero resistance); for harsh operating conditions are not sensitive to oxidation and rust risk.

Disadvantages: expensive equipment; consumables are also more expensive.

Second, the current domestic market, ultrasonic wiring harness welding manufacturers and product analysis

(A) imported products

As the more advanced foreign ultrasonic wiring harness welding technology, the current domestic market there are several well-known foreign brands and agents manufacturers, for example:

1, TELSONIC (Switzerland): its products are rare in the country.

It is said that the maximum welding cross-sectional area of its products: 160mm².

2, SCHUNK (Germany): The company's products by the Kumai Si Precision Machinery (Shanghai) Co., Ltd. agent.

Main model: Minic-II Nominal: 0.5-30mm²; Global-Splicer-40 Maximum nominal: 40mm².

3, AMTECH (USA): The company was acquired by BRANSON; SONICS (USA): Dealer is Shanghai Xingyi.

Main Model: Ultrasplice®XL0.7-2 Nominal: 0.7-28mm²; Ultrasplice®MOD-10 Nominal: 35mm².

4, TECHSONIC (Korea): sold by the Beijing special sound company.

Main Model: US-3020WS Nominal: 0.5-32mm².

(2) domestic qualified products

In recent years, the domestic ultrasonic metal welding technology has made significant progress, which on behalf of manufacturers - Foshan Shunde Chu Xin Electrical Co., Ltd. as the only professional manufacturer of ultrasonic welding equipment, also introduced three automotive wiring harness welding machine products.

1, CX-40XA ultrasonic wiring harness welder

The basic parameters: ① welding line cross-sectional area: 0.3-10mm ²; ② operating frequency 40 KHz; ③ nominal power capacity: 1000W.

2, CX-20XA ultrasonic wiring harness welder

The basic parameters: ① welding wire cross-sectional area: 0.5-25mm ²; ② operating frequency: 20 KHz; ③ nominal power capacity: 3600W.

3, CX-20XB ultrasonic wiring harness welder:

The basic parameters: ① the maximum cross-sectional area of the welding line: 40mm ²; ② operating frequency: 20 KHz; ③ nominal power capacity: 5000W.

The above is listed to meet the technical requirements of automotive wiring harness production products, which has obvious technical characteristics: ① ultrasonic generator are frequency automatic tracking (no frequency of the knob); ② line width adjustment are digital settings; ③ a variety of parameters Digital settings, storage and call functions (usually more than dozens of); ④ welding quality control software.

At present, the domestic ultrasonic wiring harness welding market there are a lot of real ones, shoddy products. Some manufacturers use the existing ultrasonic plastic welding technology circuits and transducers to do ultrasonic metal welding equipment, the equipment can not meet the technical requirements of automotive wiring harness mass production.

To a manufacturer of products as an example: ① ultrasonic generator, the obvious use of ultrasonic plastic welding B class half-bridge amplifier, do not have the frequency of automatic tracking function; ② line width manual adjustment, welding high manual adjustment limit; ③ welding pressure manual adjustment ; ④ no quality control software.

Question: ① welding head heat and with different load generated by the frequency drift, how to do? The resulting rise in the head of the welding head, how to do? ② different square wire welding parameters of each should be manually adjusted? ③ how to judge Each welding products are qualified? To know, the production of automotive wiring harness, but in large quantities. For this product, like the truck on the truck is equipped with a portable tractor engine, how to make it stable cargo?