The 8000W high-power ultrasonic welding machine YN-D208-G is specifically designed for welding 20-70mm² large wire harnesses and copper-aluminum busbars, featuring a 380V 20KHz industrial-grade configuration. Its core value lies in efficiently and stably completing large cross-section metal welding, enhancing connection strength and electrical conductivity.
Technical Specifications
Product Appearance
| Parameter Name | Parameter Value |
| Input Voltage | 380V |
| Operating Frequency | 20KHz |
| Output Power | 8000W |
| Welding Area | 20-70mm² |
| Equipment Weight | 957KG |
| Dimensions | 1750×1050×2150mm |
| Applicable Materials | Copper, aluminum, and copper-aluminum busbars |
| Working Environment | Adapts to harsh industrial environments, supports 24-hour continuous operation |
Product Features
High Power Output: Driven by 8000W high power, easily welds large-area conductors of 20-70mm², specifically designed for heavy-duty wire harnesses and copper-aluminum busbars, meeting large cross-section metal connection needs.
Precision Digital Control: Utilizes digital frequency tracking and amplitude adjustment technology to ensure extremely high welding consistency each time, effectively reducing spatter and improving yield rate.
Robust and Durable Structure: The entire machine weighs 957KG, with strong structural rigidity and excellent long-term operational stability, capable of adapting to harsh industrial environments such as vibration and dust.
Efficient Heat Dissipation System: Combines optimized airflow design with industrial-grade heat sinks, supporting 24-hour continuous high-intensity operation, ensuring stable long-term equipment performance.
Wide Range of Applications: Covers automotive high-voltage wire harnesses, new energy power cables, power distribution cabinet busbars, and IGBT module power device lead welding, offering multi-purpose use.
Applicable Scenarios
New Energy Lithium Battery Production Line
Power battery tab welding, module busbar welding, energy storage battery pack assembly, weld resistance ≤100μΩ, extensive experience in daily production line integration.
Automotive Wire Harnesses and Connectors
High-voltage wire harness terminals, motor lead wires, IGBT module welding, replacing traditional crimping, reducing contact resistance by over 60%.
Copper-Aluminum Transition Welding
Direct solid-state welding of copper-aluminum dissimilar metals without transition pieces, widely used in charging stations and the electrical power industry.
Precision Electronic Components
Micro terminal and sensor pin welding, with a minimal heat-affected zone, suitable for medical electronics and instrumentation.
Frequently Asked Questions
What materials can this ultrasonic welding machine weld?
It is mainly suitable for solid-state welding of metals such as copper, aluminum, and copper-aluminum busbars, particularly for connecting large wire harnesses, copper-aluminum busbars, and power electronic components.
What welding area does the 8000W power correspond to?
This model has a welding area range of 20-70mm², capable of efficiently handling heavy-duty wire harnesses and large cross-section conductors like busbars.
What power supply conditions does the equipment require?
It requires a 380V three-phase power supply with a frequency of 20KHz. Stable voltage is recommended to ensure long-term reliable operation of the equipment.
How is welding quality consistency ensured?
The equipment is equipped with a digital frequency tracking and amplitude adjustment system, which monitors and adjusts welding parameters in real-time, effectively reducing spatter and ensuring highly consistent welding results each time.
Is this equipment suitable for continuous production?
Yes, the entire machine features a reinforced body and efficient heat dissipation design, supporting 24-hour continuous operation, making it suitable for high-volume industrial production lines.
Is sample testing provided for first purchase? Is there a charge?
Yingna Technology provides free sample testing services: ① The customer sends welding samples and materials; ② The Yingna technical team selects suitable equipment and welding head according to material specifications; ③ Trial welding is performed and welding parameters are recorded; ④ The welded samples and welding parameter report are sent back. The sample testing cycle is usually 3~5 working days, and the cost is fully waived. After the sample test is qualified, mass production orders can use these parameters to achieve consistent production quality. When requesting sample testing, please clearly provide: material grade (copper/aluminum), wire diameter (mm²), number of layers, welding requirements (strength/resistance).
Does the ultrasonic welding machine require preheating when started? Are welding parameter settings complicated?
The ultrasonic welding machine is ready to weld immediately after startup, requires no preheating, and completes self-check within 10 seconds to enter working status. Welding parameter settings are simple: set the three core parameters of welding power (10~100%), welding time (0.01~1.0s), and welding pressure (0.1~0.7MPa) via touch screen or keys. Yingna Technology equipment supports parameter recipe storage (maximum 100 recipes); when switching product models, they can be recalled with one key, with no need for repeated settings, especially suitable for multi-variety, small-batch production.
Do ultrasonic welding machines have CE/FCC/ISO certification? Can you provide certificates?
Yingna Technology ultrasonic welding machines are certified to CE (EU electromagnetic compatibility and safety), FCC (US electromagnetic compatibility), and ISO9001 (quality management system). Equipment exported to Canada can optionally obtain CSA certification, and equipment exported to Japan can optionally obtain PSE certification. Certificate copies can be provided with the shipment or downloaded and viewed on the website. For overseas customers with special certification requirements (such as UL, SAA, etc.), certification applications can be arranged separately.
What advantages does ultrasonic welding have compared with resistance welding and laser welding?
Ultrasonic welding advantages: ① Welding time 0.1~1.0 seconds (resistance welding 2~5 seconds), efficiency increased by 3~5 times; ② Welding temperature is lower than the metal melting point (about 40~60% of the melting point temperature), with no thermal deformation and no annealing; ③ Can weld copper-aluminum dissimilar metals (difficult with resistance welding); ④ No solder/flux, clean and environmentally friendly; ⑤ Low welding resistance (≤100μΩ), excellent conductivity; ⑥ Low energy consumption, only 30~50% of resistance welding.
What is the service life of the welding horn (mold) of an ultrasonic welding machine? What to do after wear?
The welding horn (horn) is a consumable item, and its service life depends on the material and usage frequency: ① Alloy steel welding horn (T6): 50,000~100,000 welds; ② Titanium alloy welding horn (75E): 150,000~300,000 welds; ③ Wear is faster when processing aluminum (about 60% of the service life for copper). Welding horn wear affects welding quality and consistency; regular inspection of pattern clarity is recommended. After wear, replacing with a new welding horn restores welding capability; welding horn removal is simple, replacement can be completed within 10 minutes, and no return to factory is required. Yingna Technology provides custom welding horn services, customizing the optimal welding horn solution according to your wire specifications and terminal shape.
What are the main wearing parts of an ultrasonic welding machine? What is the replacement cycle?
Main wearing parts: ① Horn: replace after pattern wear; steel horn 50,000~100,000 times, titanium horn 150,000~300,000 times; ② Booster: natural wear part, normal use 2~3 years; ③ Transducer: normal use 5~8 years; ④ Ceramic ring/bolt: replace after loosening. It is recommended to regularly check bolt tightening torque (according to the specified value in the manual) to prevent thread stripping. Replacement of wearing parts is all done on site, no need to return to factory, and simple calibration after replacement restores use.
Can ultrasonic welding replace resistance welding and screw connections?
Ultrasonic welding is an upgraded solution to resistance welding and screw connections: ① Replaces resistance welding: low welding temperature, does not damage the annealed state of copper wire, lower joint resistance (≤100μΩ vs resistance welding 200~500μΩ), more reliable in long-term operation; ② Replaces screw connections: no screws, nuts, washers or other accessories required, higher connection strength (tensile breaking force ≥80% of base material), no risk of screw loosening. Especially suitable for new energy batteries, high-voltage wire harnesses and other scenarios with extremely high requirements for connection reliability and conductivity. Replacement recommendation: for high-current connections, ultrasonic welding is preferred, with mechanical connections as auxiliary.
