In the field of wire harness manufacturing, the choice of connection technology is crucial. It not only determines the electrical performance and mechanical strength of the wire harness, but also directly affects the stability and safety of the entire system. As a professional wire harness manufacturer, we have conducted an in-depth comparison of ultrasonic welding and crimping technology in order to provide customers with better quality and more reliable connection solutions.
Ultrasonic welding technology is a mature welding process that uses the mechanical vibration energy of ultrasonic frequency to achieve solid-phase welding of the same or different metals under static pressure. In this process, mechanical energy is converted into internal energy, deformation energy and limited temperature rise, so that the two parent materials are welded at the recrystallization temperature. Ultrasonic welding has many advantages:
Fast and efficient: Ultrasonic welding can be completed in a very short time, greatly improving production efficiency, and is suitable for environments that require rapid production.
Energy saving: Compared with traditional welding technology, ultrasonic welding consumes less energy and is more energy-saving and environmentally friendly.
High fusion strength: The strength of the joint after welding is close to or even exceeds that of the parent material itself, and can withstand greater external forces.
Good conductivity: The resistivity of the joint after welding is extremely low or almost zero, and the conductivity is excellent.
Environmentally friendly and safe: No sparks are generated during the welding process, which reduces the risk of fire, and no harmful substances are emitted, which is safer and healthier.
No flux and solder are required: the welding process is simplified and the cost is reduced.
In addition, ultrasonic welding technology also has a wide range of applications, suitable for filaments or thin sheets of various non-ferrous metals such as aluminum, silver, brass, bronze, copper, nickel, gold, platinum, etc. Especially in the field of electric vehicles, ultrasonic welding technology is widely used in battery packaging, cable to terminal connection and other scenarios due to its excellent capabilities.
However, crimping technology is also an important connection method. It achieves a tight connection by applying pressure to produce plastic deformation between two metal objects. The crimping process has the characteristics of firm connection, high efficiency and energy saving, environmental protection, simple structure, easy operation and maintenance. In the automotive, power, communication and other industries, the crimping process is widely used to connect wire harnesses and contacts.
The advantage of crimping technology is that it has a firm connection and can provide stable electrical performance and mechanical strength. At the same time, the crimping process does not require additional heat sources or welding materials, which reduces costs. However, crimping technology also has some challenges. For example, poor crimping may lead to problems such as too small or too large crimping height, too small or too large insulation crimping area, and loose core wires. These problems require wire harness manufacturers to conduct strict inspection and control during the crimping process.
As a professional wire harness manufacturer, we are well aware that ultrasonic welding and crimping technologies have their own advantages. In practical applications, we will choose the most suitable connection technology based on the specific needs of customers and product characteristics. For scenarios that require high strength, high conductivity, and fast production, we will give priority to ultrasonic welding technology. For some scenarios that have strict requirements on cost or require simple operation, crimping technology is a good choice.
Sejow can provide OEM/ODM Wiring Harness ，Cnc Machining Parts based on your requirements. Wiring harness, also known as Cable Harness, CNC machining parts are assembly of Cnc Milling Service which transmit signals or electrical power. In the future, Sejow will continue to uphold the business philosophy of "integrity, responsibility, and innovation", provide customers with better products and services, and work together to create a better tomorrow. Consultation hotline: 0755-29426119.
Sejow (Shenzhen) Industrial Co., Ltd.
