Ultrasonic Welding for Wire Harness & EV Terminals

Typical Applications

• EV harness terminals

• Connector insulation parts

• Fuse box / relay housings

Key Challenges

• Pull strength variation.

• Insulation parts sensitive to heat/pressure.

• High takt time and in-line QC required.

• Many terminal types, frequent changeover.

  
  

Solution Highlights

• Energy closed-loop to lock pull strength window.

• Customized horn/fixture for each terminal family.

• Auto feeding + poka-yoke positioning.

• Traceability integration if needed.

  
  

Recommended Systems

• Servo Electro Precision Ultrasonic Welder (20 kHz)

• Custom terminal welding stations / lines

• Optional laser marking / data logging combo line

  
  

Case teaser
Automatic terminal insulation welding line for EV harness.