How A Wiring Harness Splice is Ultrasonically Welded

When making a wiring harness, many times 2 or more wires need to be spliced together. The newest technology is ultrasonic welding. To make the splice shown on the bottom, an ultrasonic welder was used. That means NO terminal. NO Acid (which means no long term corrosion) and NO Solder. Yet the weld process produces strong, ultra-reliable welds, that can be monitored with software to insure that they are repeatedly accurate. Used since the late 90's, ultrasonic welding has become the industry standard and is now required by G.M., Ford, Chrysler, Mercedes, and all the major automotive manufacturers. With the traditional method of splicing - or the "Clip & Dip" method, multiple wires were first held together with a metal terminal. The splice method used TODAY in automotive wiring harness manufacturing, is ultrasonic welding. So what IS ultrasonic welding? Basically, high-frequency sound (or ultrasound) causes rapid vibrations within the wires to be welded. The vibrations (up to 20 thousand times per second) cause the wires to rub against each other. This friction raises the temperature at the wire surfaces and sets the conditions for the wires to form a molecular bond to one another. Parameters like wire quantity, gauge, orientation to the weld, weld height before the weld, after the weld, the time used to make the weld, pressure, aplitude, energy put into the weld, and the width of the weld. After the ultrasonic splice is made, it is covered with tape or rubber mold, per the original manufacturer's specifications.

• #autos_vehicles
• #ultrasonic
• #welding
• #stapla
• #telsonic
• #wiring
• #harness
• #splice
• #automotive
• #splicing