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How to Weld Terminals of New Energy Charging Gun Harness
Aug 13,2026
New energy charging guns transmit large continuous current during operation. Long-term vibration and alternating cold & hot environments easily cause joint overheating, cold solder joints and wire detachment. Ultrasonic metal welding is the mainstream optimal process for thick main wires of charging guns.
I Advantages of Ultrasonic Welding
This process uses high-frequency mechanical vibration plus pressure to break metal oxide layers and tightly bond copper wires and terminals without solder or flux. Welding generates little heat and will not burn wire insulation. Welded joints are compact with low resistance, resisting overheating under long energization, vibration and fatigue well.
II Pre-Workpiece Preparation
1.Standard wire stripping: Control stripping length matching terminal size; fully insert core wires into welding zone, insulation must not enter welding area. Avoid scratching or cutting copper strands during stripping; prevent loose/flying wires which cause short circuits and poor contact later.
2.Clean wire cores: Remove oil, dust and black oxide layers on copper surfaces after stripping.
3.Neat wire arrangement: Gather scattered multi-strand copper along original texture, lay evenly without unilateral accumulation or skew to ensure uniform stress & heat during welding.
III Ultrasonic Welding Operation Flow
1.Fixture Positioning: Place terminals steadily, center harness on terminal welding zone and clamp firmly without shifting to avoid uneven welding stress.
2.Low-pressure Pre-compression: Flatten loose wires gently and expel air between strands to eliminate internal hollow gaps and cold joints fundamentally.
3.Formal Welding: Match proper vibration amplitude & welding time to realize metal atomic bonding for solid, compact joints.
4.Pressure Holding Forming: Release internal welding stress after welding to prevent copper rebound and tiny joint cracks, boosting tensile strength & stability.
5.Natural Cooling: Let workpieces stand to cool after welding; do not pull wires before cooling to avoid loose joints.
IV Key Parameter Tuning Tips
1.Welding Pressure: Insufficient pressure fails to fully break oxide layers, causing cold joints and heating when energized; excessive pressure crushes & snaps wires, lowering joint tensile strength. Use moderate stable pressure to achieve tight contact without wire damage.
2.Vibration Amplitude: Match amplitude to wire gauge. Insufficient amplitude leads incomplete fusion; excessive amplitude over-deforms copper and accelerates horn wear.
3.Welding Time: Too short causes inadequate metal diffusion & weak joints; too long damages wires & terminals with deformation & broken strands.
V Common Defects & Causes
1.Loose joints, easy pull-off, high resistance & overheating: Dirty/oxidized wire cores or insufficient welding energy, offset harness placement.
2.Burned insulation: Excessively large heat-affected zone or overlong welding time.
3.Crushed/broken wires, low tensile strength: Overhigh pressure or vibration amplitude.
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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