20kHz 6500W Ultrasonic Wire Harness Welding Machine

20kHz 6500W Ultrasonic Wire Harness Welding Machine

Product Description

ACEY-UWM-20-6500 ultrasonic wire harness welding machine joins wire ends through ultrasonic vibration and pressure. It is used in automotive wire harness production, battery module wiring and other electrical connection applications. The machine operates at 20kHz with a rated power of 6500W, and the upper welding horn is matched to the wire size and joint requirements.

The DSP circuit and ICS digital control system support continuously adjustable ultrasonic amplitude, energy and time welding modes, and automatic frequency tracking. Operators can set and recall welding parameters through the 7-inch touchscreen when switching between validated welding jobs. Multi-level password protection separates routine operation from process adjustment.

The machine uses pneumatic drive and a separate welding head and generator structure for installation and maintenance. Voltage, overcurrent and welding overload protection monitor system operation. Welding results can be output through a standard communication protocol, with an interface provided for MES integration.

Product Features

• 20kHz ultrasonic system with 6500W rated power: Configured for the specified copper wire-to-strip welding applications in battery module assembly.
• Adjustable welding parameters: Continuously adjustable ultrasonic amplitude, with energy and time welding modes for different process requirements.
• Preset parameter recall: Supports multiple welding parameter presets, allowing operators to recall settings for validated welding jobs.
• Digital process control: The ICS system provides millisecond-level sampling, startup self-check and automatic frequency tracking during operation.
• 7-inch touchscreen: Provides a graphical interface for parameter adjustment, machine operation and welding result display.
• Welding data output: Supports welding result output through a standard communication protocol and provides an interface for MES integration.
• System protection: Includes voltage protection, overcurrent protection and welding overload feedback.
• Multi-level password protection: Separates operator access from parameter adjustment and management functions.

Battery Module Welding Applications
This configuration is intended for welding copper wires to nickel-plated copper strips during battery module assembly. Reference applications include main module connection wires and CCS wires.

The weld mark dimensions are process references for the specified application. Final tooling and welding settings depend on the wire construction, strip thickness, material condition and available welding space.

Pouch Battery Pack Welding Results

Technical Specifications

Service and Support

ACEY provides a one-year equipment warranty under the agreed warranty terms, together with operation and maintenance training. Training covers equipment structure, normal operation, routine maintenance, troubleshooting and emergency procedures. Continued technical service is available after the warranty period.

Product Display

FAQ
1. Do we need to change the welding horn when switching wire sizes?
Yes. Different wire sizes require matching upper welding horns. For AWG 8, AWG 12 and AWG 20 wires, a corresponding upper welding horn is required for each size.

2. Do operators need to enter the welding parameters again for every job?
No. The machine supports multiple preset welding parameters. Once a process has been set and validated, operators can recall the corresponding settings through the touchscreen. Parameter adjustment can be restricted using password access levels.

3. Can we collect welding results through our factory MES?
The machine provides welding result output through a standard communication protocol and an MES interface. Please share your MES communication requirements and required data fields so the integration scope can be confirmed before ordering.