Dhruvs Ultrasonics

Dhruvs Ultrasonic: 20kHz / 5000W Ultrasonic Wire Harness Welding Machine

The Dhruvs Ultrasonic 20kHz/5000W is a high-capacity industrial system specifically engineered for the high-performance demands of the automotive and power electronics industries. This machine utilizes ultrasonic metal welding technology to create a solid-state molecular bond between non-ferrous metal wires, such as copper and aluminum. With a massive 5000W power reserve, it is designed to handle large cross-sectional area wire splices with unmatched conductivity and mechanical strength.

Core Specifications Advanced Technical Features

• High-Power 5000W Digital Generator: Equipped with a state-of-the-art digital power supply that provides stable energy delivery even under the high-pressure loads required for large wire bundles. It features automatic frequency tracking to ensure the 20kHz resonance is maintained throughout the weld.

• Precision Splice Width Adjustment: The machine includes a high-precision mechanical adjustment system that allows operators to set the exact width and height of the wire splice, ensuring consistent dimensions for every harness.

• Oxide-Breaking Technology: The high-frequency mechanical friction effectively breaks through surface oxides and contaminants on the wire strands, creating a clean metal-to-metal bond without the need for solder or crimp terminals.

• Intelligent Height & Energy Monitoring: A built-in linear encoder monitors the "collapse height" of the wire bundle in real-time. If the weld does not reach the specified height or energy parameters, the system triggers an instant alarm to prevent defective parts from leaving the station.

• Durability-Focused Tooling: Features a high-tensile steel anvil and welding tip (sonotrode) designed for quick replacement and extended life, even when processing high volumes of heavy-gauge copper wiring.

Key Benefits for Automotive & EV Manufacturing

1. Superior Conductivity: Because no third-party material (like solder) is introduced, the electrical resistance of the splice is nearly zero, ensuring maximum current efficiency in high-voltage EV circuits.

2. Heat Resistance: The molecular bond created by ultrasonic welding has a melting point equal to the parent metal, making it far superior to soldering for high-temperature environments.

Primary Applications

This 5000W powerhouse is optimized for heavy-duty wiring requirements:

• Electric Vehicles (EV): High-voltage battery cables, busbar connections, and charging port harnesses.

• Automotive Main Harnesses: Splicing multiple wire strands into a single junction for main power distribution.

• Solar & Wind Energy: Connecting heavy-gauge copper wiring in renewable energy inverters and control panels.

• Engineering Insight: To achieve a perfect splice with 25 $mm^2$ cables, the 5000W system applies a specific "stepping" of energy to ensure the center of the wire bundle is fused as securely as the outer strands. Dhruvs Ultrasonic provides custom-designed tips for specific wire gauges to ensure 100% weld integrity.

Additional Information:

• Item Code: USME
• Production Capacity: 100
• Delivery Time: 15