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What Are The Welding Processes Of Automotive Wiring Harness?

The welding processes of automotive wiring harness includes Crimping,ultrasonic welding,wire harness welding, wire harness brazing etc. Let us learn the knowledge of ultrasonic wire harness welding together.

1. Wir harness crimping

The most widely used type on the market, crimping is the use of terminals to press multiple strands of wire together to form a joint. Under pressurized conditions, the two workpieces achieve atomic bonding in the solid state, also known as solid state welding. The commonly used pressure welding process is resistance butt welding. When the current passes through the connection end of the two workpieces, the temperature rises due to the large resistance, and when heated to the plastic state, the connection is integrated under the axial pressure. The advantage is that no filling material is required, the production speed is fast, and the equipment is simple; the disadvantage is that there is a risk of rebound in metal stamping, oxidation and rust under severe working conditions, and all risks may lead to poor contact.

2. Ultrasonic wir harness welding

Nowadays, a more popular ultrasonic welding is to use a combination of the physical effects of ultrasonic vibration to combine the wire ends. The application of automobile wire harness is the first popular in Europe and America. The principle is that the mold can emit vibration frequency of 20,000-40,000 times per second, which can make the wires at both ends evenly connected, and when the wire is quickly vibrated and rubbed, heat will be generated to make the link stronger. The advantage is superior electrical connection characteristics (basic zero resistance), which is insensitive to the risk of oxidation and rust under severe conditions, and the tensile strength and tear strength are in line with high requirements, which can be quickly installed and make the cost minimized. The disadvantage is that ultrasonic wire harness equipment is expensive as well as consumables (wire harness molds). Unusual copper wire harness welding process welding advantages of welding materials are not melted, not fragile metal properties. Good electrical conductivity after soldering, very low or nearly zero resistivity. Low requirements for welding metal surface, oxidation or electroplating can be welded, welding time is short, no flux, gas, solder, no sparks, environmental protection and safety.

3. Wire harness welding

The workpiece interface is heated to a molten state during the welding process, and the welding method is completed without pressure. The wire harness joints are welded together to form a weld bead, and the electric resistance is large, which greatly reduces the service life of the wire harness.

4. Wire harness brazing

Using a metal material lower than the melting point of the workpiece as a brazing material, the workpiece and the brazing material are heated to a temperature higher than the melting point of the brazing material and lower than the melting point of the workpiece, and the workpiece is wetted by the liquid brazing material, filling the interface gap and achieving atomic interaction with the workpiece. The method of mutual diffusion to achieve welding. It is easy to cause overheating, embrittlement, hardening or softening.