Wire Harness & Connector Welding Solutions | Reliable ultrasonic welding for stable electrical and mechanical connections

Intro

Wire harnesses and connectors are critical to electrical reliability and system safety in automotive industrial

and electronic applications.

For EU and US end-use factories and specialized harness manufacturers, welding solutions must ensure 

consistent pull strength, precise alignment, and repeatable electrical performance, especially in high-volume 

production environments.

Our wire harness and connector welding solutions are designed to deliver controlled ultrasonic energy, 

stable joint quality, and high process repeatability, helping manufacturers reduce defects and improve 

long-term connection reliability.

Typical Applications

• Automotive wire harness assemblies

• Electrical connectors and terminals

• Cable-to-terminal ultrasonic welding

• Multi-wire harness joints

• Power and signal cable assemblies

• Industrial wiring and control cable connections

Key Challenges

• Inconsistent pull force can lead to connection failure

• Wire misalignment increases the risk of weak or false welds

• Variations in wire cross-section affect welding stability

• High-volume production requires strict repeatability

• Manual processes increase defect and rework risk

Solution Highlights

• Controlled ultrasonic energy output ensures consistent weld strength across wire variations

• Precision alignment fixtures maintain accurate positioning of wires and connectors

• Rigid mechanical structure minimizes vibration and process deviation

• Automatic frequency tracking maintains optimal welding performance under varying loads

• Digital process parameter control supports repeatable and stable production

Recommended Systems

Ultrasonic Welding Machine for Wire Harness & Connector Applications

• Optimized for cable and terminal ultrasonic welding

• Stable output for consistent pull force and electrical reliability

• Suitable for continuous, high-volume harness production

Custom Fixtures & Automation Options

• Dedicated wire positioning and clamping fixtures

• Semi-automatic or fully automated loading solutions

• System configuration customized to wire type and cross-section

  
  

Application Scenario

High-reliability ultrasonic welding for wire harness and connector assemblies

Designed to deliver stable mechanical strength and electrical conductivity throughout long-term production cycles.

Need Stable and Repeatable Wire Harness Welding?

We support wire harness manufacturers and end-use factories with:

• Sample welding tests using your actual wires and connectors

• Pull force and process feasibility evaluation

• Customized fixture and system recommendations

Send your wire harness sample or drawing for evaluation

Get technical feedback from our ultrasonic welding engineers