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- KSG ultrasonic cable welding machine
KSG ultrasonic cable welding machine
The KSG high-performance cable harness welding machine was developed to create reliable connections for large-cross-section high-voltage cable harnesses with a cross-sectional area greater than 95 mm². It is suitable for cable-to-cable, cable-to-terminal, and terminal-to-terminal welding, as well as for large-area welding applications on thicker copper and aluminum sheets.
Scope
Cable-to-cable welding, cable-to-terminal welding, terminal-to-terminal welding, and large-area welding of copper and aluminum sheets (copper conductors 95/120 mm²; aluminum conductors up to 160 mm²)
Product advantages
- Two-channel system with a total power output of approximately 11,000 W; copper conductors up to 120 mm² and aluminum conductors up to 160 mm², covering the entire cross-sectional area range of high-voltage wiring harnesses in new-energy vehicles
- Fully digital control: Frequency, amplitude, pressure, and energy can be precisely controlled; complete data traceability
- Custom sonotrodes, welding teeth, anvils, and adjustable fixtures for various conductor cross-sections and terminal types
- Manual or fully automatic operation is possible; supports various feed types and directions
- Optional online vibration monitoring system for wire harness weld quality, designed for comprehensive process monitoring
Technical data
| Parameter Name | Specification Value |
| Ultrasonic frequency | 20 kHz |
| Maximum output power | 14,000 W |
| Total capacity of the dual-channel system | ≈ 11,000 W |
| Amplitude Adjustment | 50 % to 100 % |
| Maximum weldable conductor cross-sectional area | 160 mm² (aluminum conductor) / 95–120 mm² (copper conductor) |
| Weldment | 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 |
Connecting wires for electrical appliances, automobiles, and motorcycles; copper-to-copper and copper-to-aluminum connections; single-wire-to-multi-wire connections; braided wire and tinned wire connections
Soldering small copper and aluminum conductors to various standard terminals (copper conductors ≤ 25 mm²)
Welding of copper and aluminum conductors to copper/aluminum terminals; welding of stranded conductors to copper terminals; busbar tab welding (copper conductors 16–70 mm²)
