6500W Ultrasonic Wire Harness Welding Machine for Battery Module Wiring and Copper Wire Welding

ACEY-UWM-20-6500 6500W Ultrasonic Wire Harness Welding Machine is designed for battery module wiring, battery pack assembly, and automotive wire harness manufacturing. It enables ultrasonic joining of copper wires and compatible metal strips, including nickel-coated copper strips, without relying on conventional fusion welding. Equipped with adjustable ultrasonic amplitude, programmable welding modes, pneumatic operation, and a 7-inch touchscreen, this machine helps manufacturers configure welding parameters for different production requirements. Automatic frequency tracking, verload protection, and MES-compatible data communication support process monitoring and production integration. For manufacturers seeking an ultrasonic welding solution for wire-to-metal connections, welding samples and material compatibility can be evaluated before confirming the final configuration.

1. 6500W Ultrasonic Welding System: Designed for wire harness and battery module welding applications requiring high-power ultrasonic output.

2. Copper Wire Welding Compatibility: Supports welding copper wires to compatible nickel-coated copper strips, subject to wire specifications and process validation.

3. Adjustable Welding Parameters: DSP-based amplitude adjustment and preset parameters allow configuration for different materials and wire sizes.

4. Multiple Welding Modes: Supports energy-based and intelligent time-based modes to accommodate different process requirements.

5. Automatic Frequency Tracking: Tracks operating frequency to help maintain consistent welding conditions.

6. Precision Mechanical Structure: German-style X-rail head design supports controlled mechanical movement during welding.

7. Pneumatic Operation: Operates with a recommended compressed-air pressure of 0.4–0.6 MPa.

8. Integrated Safety Protections: Includes voltage protection, overcurrent protection, and welding overload feedback.

9. 7-Inch Touchscreen Control: Simplifies parameter setting, operation, and welding result viewing.

10. Production Data Integration: Provides standard communication interfaces and an MES interface, subject to integration requirements.

11. Parameter Preset and Recall: Allows operators to save and retrieve welding settings for repeat production tasks.

12. Startup Self-Test and Access Control: Supports equipment status checks and multi-level password management.

Q1: What materials and wire sizes can this ultrasonic welding machine process?

The ACEY-UWM-20-6500 is designed for compatible metal joining applications, including copper wires and nickel-coated copper strips. The supplied process reference specifies AWG10 wire with a 0.2–0.3 mm nickel-coated copper strip and a 6 × 8 mm welding area. Final compatibility should be confirmed through sample testing.

Q2: Can the machine weld copper wire directly to an aluminum tab?

Direct copper-to-aluminum ultrasonic welding is not included in the current acceptance criteria because of material compatibility and tool adhesion challenges. The recommended process is to evaluate a nickel-coated copper transition strip before welding to the copper wire. Buyers requiring direct aluminum-tab welding should discuss feasibility and sample validation with the manufacturer before ordering.

Q3: What should buyers confirm before purchasing this ultrasonic welding machine?

Buyers should confirm wire gauge, strip material and thickness, welding area, required output, and production cycle requirements. The machine uses a 220 VAC ±10% single-phase power supply and requires compressed air at 0.4–0.6 MPa. For automated production lines, buyers should also confirm communication protocols and MES integration requirements.