HF-WX-20WD Ultrasonic Wire Harness Terminal Welding Machine

A wire harness terminal joint must provide sufficient mechanical strength while maintaining reliable electrical conductivity throughout production. The HF-WX-20WD uses ultrasonic vibration and controlled pressure to form metal connections without conventional soldering. This solid-state joining process is ideal for conductive wire and terminal assemblies requiring controlled heat input and consistent joint formation.

Available in 3 kW or 6 kW ultrasonic power configurations, the machine supports a welding range of 2-35 mm². The optimal configuration depends on conductor material, terminal structure, wire cross-section, and required weld geometry.

For wire harness terminal welding, the welding machine is only one component of the complete solution. Proper terminal and wire positioning during the ultrasonic welding cycle is critical for consistent joint formation.

Haifei evaluates tooling according to:

For products with multiple terminal specifications, interchangeable or dedicated tooling solutions are available based on production methodology.

Haifei recommends a practical validation process for new wire terminal applications:

Provide wire material specifications, cross-sectional area, terminal drawings, and welding position requirements.

Use actual wire and terminal samples to establish optimal welding parameters.

Evaluate welded connections against mechanical, electrical, and dimensional criteria.

Adjust horn, anvil, and fixture designs based on validated joint performance.

Finalize machine configuration for required production methodology and output after process validation.

Haifei manufactures intelligent welding equipment and customized welding automation solutions, including ultrasonic welding, resistance welding, diffusion welding, and automated welding systems.

For wire harness terminal projects, equipment development focuses on the actual joint requirements rather than standalone standard machines. Haifei provides comprehensive support throughout:

The published welding range is 2-35 mm². Actual range for specific wire and terminal combinations should be confirmed through welding trials.

The appropriate version depends on wire cross-section, material combination, terminal structure, and required weld area specifications.

Yes, wire-to-terminal welding is the primary application. Terminal shape and wire structure should be provided for tooling and process evaluation.

No. Ultrasonic metal welding forms connections through vibration and pressure, eliminating the need for conventional solder or flux.

Different terminal specifications can be accommodated through appropriate tooling and production configuration. Product variants and changeover requirements should be confirmed during project evaluation.

Have a wire-to-terminal application to develop? Provide Haifei with your wire specifications, terminal drawings or samples, welding requirements, and target production volume.

Our engineering team will evaluate your joint requirements, conduct sample welding, and recommend optimal ultrasonic wire harness terminal welding configurations.