Welding cables with ultrasound
A chain is as strong as its weakest link. The same goes for wiring harnesses. Only a wiring harness does not have links but connections between the various cables. These connections must be rock solid. By welding the cables together with “sonic wire welding,” or welding with ultrasound, top quality of the entire wiring harness is assured.
How does it work?
‘Sonic wire welding’ (or ultrasonic welding) is an elegant welding method; by sending sound waves through a bundle of wire ends, the whole thing flows together. The result is a precise strong compound at the molecular level.
What are the benefits
Traditional welding creates risk of distortion or burns from heat. Especially when welding thin metals and delicate components. Ultrasonic welding does not involve heat but ultrasound with a specific sound frequency for copper. Sound waves are sent through the beam of metals causing the copper molecules to vibrate minimally. As a result, the metal flows together to form a very solid joint. Well, connection…actually there is one totally fused together. Thus, the “weld” is no longer a “link,” let alone a weak link.
Major advantage of “sonic wire welding” is high productivity with consistent quality. This makes the process ideally suited for the production of large batches of wire harnesses. ‘Sonic wire welding’ is also thoroughly reliable: The process does not depend on the qualities of the operator. Last but not least, “sonic wire welding” is extremely precise and never deforms the material. Hence, this technique is used where precision, strength and quality are vital such as in the medical industry and in aerospace engineering. The use of this very clean technique also has the added advantage that no waste products are released (smoke or vapor). Ventilation and cooling are therefore not necessary.
Is it suitable for my products?
In summary, ultrasonic welding is a fast, efficient, clean and accurate method for joining wires. Ideal for the production of large runs of wire harnesses where precision, strength and top quality are requirements. And let these be exactly the goals StekkerSnel pursues.
No surprise, then, that PlugFast works with ultrasonic welding equipment. Wondering how StekkerSnel can apply this technique to your products?
Send your sound waves to PlugFast and we’ll explain.
