Adjustment of Parameters for Ultrasonic Wire Harness Welding Machine

Adjustment of Parameters for Ultrasonic Wire Harness Welding Machine

Parameter Adjustment, Testing, and Analysis for Ultrasonic Wire Harness Welding Machine

Parameters are adjustable and measurable: amplitude, pressure, welding time, welding energy, 

welding height, welding width.

Pressure: The larger the cross-sectional area, the higher the welding pressure. A good device is digitally

 controlled by an electric proportional valve.

Welding Width: According to IPC standards and the German Volkswagen standard VW60307-CN-2005, 

the aspect ratio of the weld nugget width to thickness should be between 1:1 and 2:1. The larger the 

cross-sectional area, the closer the width and thickness of the nugget are to 2:1. Therefore, when we 

receive wire harness products, we first determine the welding width based on this rule; then, based on

 the width, we determine an approximate welding height. The welding machine uses a stepper motor

 or servo motor to adjust the welding width.

Welding time and welding energy need to be determined by trial welding based on the cross-sectional

 area of the wire. The height parameter is an important analysis parameter: Once we have determined 

the welding width, based on the previous analysis, we can calculate the height value. The height before

 and after welding can serve as criteria for judging whether there is missing wire before welding and 

whether the welding is satisfactory.

Quality analysis mainly refers to height determination; of course, welding energy consumption and time 

can serve as additional constraint parameters to see if they exceed the range. General practice: set aheight

 value (which can be determined through actual trial welding calculations), then set a deviation value. When

 the height deviation exceeds the range, it can be considered as non-compliant. This applies before and after

 welding as well.