With the advancement of technology, new energy vehicles, including pure electric vehicles and hybrid vehicles, have developed rapidly, and there is a trend for new energy vehicles to replace traditional fuel vehicles. New energy vehicles driven by electricity cannot do without the role of high-voltage harnesses, which safely and reliably transmit the electrical energy required to drive the vehicle. As is well known, long battery charging time is one of the key factors limiting the growth of the electric vehicle market. Normally, electric vehicles require several hours of charging time to achieve range, while traditional fuel powered vehicles or trucks can quickly fill up with gasoline or diesel to ensure range. In order to shorten the charging time of electric vehicle batteries, electric vehicle manufacturers need to improve the ability of the circuit in the charging system to carry high voltage and high current, which relies on cables with high current carrying capacity to achieve. Therefore, wire harnesses with large cross-sectional areas are widely used to flow higher currents while also having good heat dissipation ability, which is an effective method to improve the charging efficiency of electric vehicle batteries.
The current carrying capacity of high-voltage wiring harnesses for future electric vehicles will be four to five times that of existing ordinary electric vehicle cables. In terms of wire harness size, if copper is chosen as the conductor material, the cross-sectional area of the wire harness used will increase from 50mm2 to 200mm2, or even higher.
application area
However, how to reliably connect these larger cross-sectional cables is a major technical challenge that car manufacturers need to face. At the same time, the rapid updates and iterations of electric vehicles have also brought about the exploration of technical points such as how to arrange and accommodate these cables, cable lengths, and low internal resistance connection processes inside the car. Ideally, the shorter the cable length, the better, in order to achieve low internal resistance and low temperature rise performance. However, in reality, it is usually not possible to shorten the cable length inside electric vehicles, so the cable diameter needs to be correspondingly increased to ensure low internal resistance and good heat dissipation. As more and more battery modules are arranged below the vehicle, larger cross-sectional wire harnesses or conductors need to be installed and arranged around and below the passenger compartment. Therefore, the body structure must not only be insulated from cables and conductors, but also safely dissipate the temperature rise generated by the wiring harness during rapid charging.
Car wiring harnesses are the main network of car circuits and the neurons that enable normal operation of cars. Without wiring harnesses, there would be no automotive circuits. Traditional automotive wiring harnesses refer to components that are formed by bundling copper contact terminals (connectors) and wires and cables, which are then crimped together with insulation or metal shells, to form a connecting circuit.
With the entry of automotive electronic products and various communication devices into automobiles, the requirements for the electrical signals transmitted by automotive wiring harnesses are becoming increasingly stringent. To meet the requirements of high-precision voltage and signal transmission, traditional wire harness manufacturing processes use some special materials, such as twisted pair, shielded wire, gold-plated terminals, etc. However, it still appears ineffective on most electronic control devices and some special signals, such as CAN controller signal transmission lines, airbag signal transmission lines, and some audio signal transmission lines. Although the existing terminal wire crimping process uses the above special materials, occasional signal distortion or significant attenuation still occurs in the above-mentioned signal transmission lines.
Solution focus
In fact, whether it is the wire or the terminal and wire that are pressed by ultrasonic waves, they are in a rectangular shape at the crimping point, without loose core wires or broken or cracked core wires; Moreover, the wire is not bent, but leads out in a straight line at the self fusion point. Ultrasonic welding is the process of melting adjacent metal surfaces to form a fusion between metal molecular layers, which is equivalent to melting adjacent metals into a whole. Compared to terminal crimping where adjacent copper wires remain independent metal entities, the density of the welding area is better and there are no voids. Good conductivity, extremely low or almost zero resistance coefficient, effectively improving durability, less prone to heating, and no quality hazards.
Advantages of ultrasound over traditional solutions
Firstly, solve the voids formed by terminal crimping, improve conductivity and stability of the entire electrical system.
Secondly, it reduces the accumulation of heat caused by contact resistance, preventing quality hazards such as local temperature rise and harness burning.
Thirdly, it prevents the wires in the wiring harness from being affected by external factors such as moisture, dust, oil and gas, which can cause copper wire corrosion and oxidation, leading to a decrease in conductivity and signal transmission distortion.
Our strengths
1. Short welding time, greatly improved efficiency, fast and energy-saving;
2. The characteristics of non melting and non fragile conductors in welding materials;
3. After welding, the conductivity is superior, the strength is high, and the resistance system is extremely low or almost zero;
4. No flux, gas, or solder required;
5. Welding without sparks or smoke, environmentally friendly and safe;
6. Stable welding process, online detection and control.
