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- KSG Ultrasonic Cable Welding Machine
KSG Ultrasonic Cable Welding Machine
The KSG high-power wire harness welding machine was developed for reliable connections of large cross-section high-voltage wire harnesses exceeding 95 mm². It is suitable for cable-to-cable, cable-to-terminal, and terminal-to-terminal welding, as well as large-area welding applications on thicker copper and aluminum sheets.
Application Range
Cable-to-cable welding, cable-to-terminal welding, terminal-to-terminal welding, and large-area welding of copper/aluminum sheets (copper conductors 95/120 mm²; aluminum conductors up to 160 mm²)
Product Advantages
- Dual-channel system with a total output of approx. 11,000 W; copper conductors up to 120 mm² and aluminum conductors up to 160 mm², covering the full cross-section range of high-voltage wire harnesses in new energy vehicles
- Fully digital control: frequency, amplitude, pressure, and energy are precisely adjustable; complete data traceability
- Custom sonotrodes, welding tips, anvils, and adjustable fixtures for different conductor cross-sections and terminal types
- Manual or fully automatic operation; supports various feeding methods and directions
- Optional online vibration monitoring system for wire harness welding quality and comprehensive process monitoring
Technical Specifications
| Parameter | Specification |
| Ultrasonic Frequency | 20 kHz |
| Maximum output power | 14,000 W |
| Dual-Channel System Total Power | ≈ 11,000 W |
| Amplitude Adjustment | 50% ~ 100% |
| Max. Weldable Conductor Cross-Section | 160 mm² (aluminum conductor) / 95–120 mm² (copper conductor) |
| Weld Object | Copper conductors, aluminum conductors, copper/aluminum terminals |
| Welding Mode | Time Mode (Duration) / Energy Mode (Energy) |
| Power Supply | 380 V |
| Air Pressure | 0.6 MPa |
| Control Type | Industrial PC (IPC) |
| Data Traceability | Supported (traceable) |
| Protection Mode | Password Protection + Parameter Protection |
| Vibration Monitoring System | Optional |
For small conductor cross-sections and compact cable connections in the electronics, automotive, and electrical engineering industries.
Soldering small copper and aluminum conductors to various standard terminals up to 25 mm²
Welding of copper and aluminum conductors to copper and aluminum terminals, braided conductors to copper terminals, and busbar tabs. (Copper conductors: 16–70 mm²)
