Ultrasonic Wire Harness Welding Machines
Ultrasonic welding joins stranded copper to stranded copper, or wire to a terminal or busbar, without solder, flux or added material. A sonotrode presses the strands while oscillating at ultrasonic frequency, and the resulting joint is a solid-state bond whose quality is judged by cross-section and pull force. It replaces crimped splices where the joint must carry high current or must not introduce a dissimilar metal — which is why it appears in battery, EV and heavy-gauge harness work. On our thermal protector welding machine, output is 850 pcs/h on AWG16#–AWG26# copper wire, with vibratory bowl feeding and multi-stage inspection rejection.
Process chain
- 1
Wire bundle aligned
- 2
Ultrasonic weld (sonotrode + anvil)
- 3
Cross-section · pull-force check
- 4
Housing insertion
- 5
Offload
The weld parameters — amplitude, pressure, energy and time — are stored per application and recalled by part number; a joint that passes pull test but shows an incomplete cross-section is still rejected.
Product lines in this family
Welding Machine
Family entry point: ultrasonic welding of wire splices, wire-to-terminal and wire-to-busbar.
View machinesProtector Welding Machine
Thermal protector welding with vibratory bowl feeding and in-line inspection rejection — 850 pcs/h on AWG16#–AWG26# copper wire.
View machinesFully‑automatic welding & housing‑inserting machine
Welds and inserts the housing in one automatic cycle, so the joint is never handled loose.
View machinesIndustries served
Choosing within this family
Choose ultrasonic over crimp when the joint must not add a dissimilar metal.
A crimped splice introduces a third material; an ultrasonic weld does not.
Weld area is the sizing parameter — not machine power alone.
Give the bundle cross-section; the sonotrode and anvil are chosen from it.
The anvil pattern is application-specific.
Wire-to-wire, wire-to-terminal and wire-to-busbar use different tooling, and a change of application can mean a change of tooling.
Decide whether inspection is per-batch or per-piece.
Multi-stage rejection in-cycle is a different machine from a bench welder with an operator pull test.
Housing insertion after welding protects the joint.
Handling a welded splice as a loose part risks disturbing the strands before the housing locks them.