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Troubleshooting Methods for Cold & False Solder Joints on New Energy Harnesses by Ultrasonic Metal Welders
Jul 17,2026
With the advantages of high efficiency, environmental friendliness, low temperature and filler-free bonding, ultrasonic metal welders have become core equipment for new energy harness welding, widely adopted in new energy vehicles and energy storage industries. Defects such as cold joints and false welds on harnesses easily lead to overheating, wire detachment and potential safety hazards. The troubleshooting procedures are listed below.
I Typical Characteristics of Cold & False Solder Joints
1.Dull solder nuggets without fusion luster; inner wires of harness fail to fully interdiffuse and separate under tension; indentations are uneven or too shallow; connectors heat up after power-on.
2.Some joints feature smooth surface and normal indentations with no looseness under slight shaking, yet cross-section inspection shows only superficial adhesion of inner wires without proper collapse after welding.
II Rapid Root Cause Investigation
1 Check Surface Visible Causes
Inspect whether harness pre-treatment and operating procedures are standardized; conduct simple tension test and visual inspection for preliminary defect judgment.
2 Inspect Equipment & Tooling Issues
Verify whether welding amplitude, time and pressure match workpieces; check horn condition and perform targeted parameter verification.
3 Inspect Core Component Status
Examine transducer and generator operation, confirm normal online monitoring system to eliminate cold/false welding caused by component failures.
III Defect Confirmation & Recurrence Prevention
1.Adjust parameters, standardize operations or overhaul components according to identified root causes.
2.Conduct verification welding tests to guarantee qualified nuggets.
3.Establish closed-loop prevention mechanism to avoid repeated identical defects.
IV Troubleshooting Precautions
1.Cut off power supply and wait for horn cooling before inspection; wear protective gear to prevent scalds and scratches.
2.Do not touch solder nuggets directly during visual inspection; keep magnifying glass clean to avoid misjudgment.
3.Ensure tight probe contact for resistance testing; never test while equipment is running to prevent electric shock.
4.Do not disassemble equipment parts arbitrarily; malfunctions must be handled by professional technicians and keep machine idle during inspection.
5.Record all troubleshooting data and build ledgers for later traceability and parameter optimization.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com