The 6000W high-power ultrasonic welding machine YN-D206-G is specially designed for welding copper and aluminum terminals of new energy vehicle wiring harnesses, achieving solid-state metal bonding through high-frequency vibration. The equipment has obtained CE certification, ensuring weld strength and conductivity, meeting high-reliability production requirements.
Technical Specifications
Product Appearance
| Parameter Name | Parameter Value |
| Input Voltage | 220V |
| Operating Frequency | 20KHz |
| Output Power | 6000W (Optional: 2000W/4000W/6000W/8000W/12000W) |
| Welding Area | 15-50mm² |
| Machine Dimensions | 1400×760×2000mm |
| Machine Weight | 192KG |
| Applicable Metals | Copper, Aluminum, and Dissimilar Metals |
Product Features
6000W High-Power Output: Covers a welding area of 15-50mm², meeting high-strength operation requirements such as high-voltage wiring harnesses and large-section copper-aluminum terminals, significantly improving production line efficiency.
Digital Control System: Precisely adjusts welding parameters (time, energy, amplitude, etc.), monitors welding quality in real-time, effectively increasing yield rate and reducing scrap rate.
Heavy-Duty Structural Design: The machine weighs 192kg, paired with a high-rigidity frame, ensuring stable and reliable operation with minimal vibration deviation, guaranteeing welding consistency.
Flexible Multi-Power Options: Supports power module expansion from 2000W to 12000W, allowing flexible upgrades based on production scale, avoiding equipment idle waste.
Dissimilar Metal Welding Capability: Compatible with welding copper, aluminum, and copper-aluminum dissimilar metals without additional pretreatment, reducing raw material procurement costs.
Optimized for High-Voltage Wiring Harnesses: Designed for high-reliability electrical connection scenarios such as automotive and aerospace, achieving low-resistance, high-strength termination processes.
Application Scenarios
New Energy Lithium Battery Production Lines
: Welding of power battery tabs, module busbars, and energy storage battery pack assemblies, with weld resistance ≤100μΩ, backed by extensive daily production line experience.
Automotive Wiring Harnesses and Connectors
: Welding of high-voltage wiring harness terminals, motor lead wires, and IGBT modules, replacing traditional crimping, reducing contact resistance by over 60%.
Copper-Aluminum Transition Welding
: Direct solid-state bonding of copper-aluminum dissimilar metals without transition pieces, widely used in charging piles and the electrical power industry.
Precision Electronic Components
: Welding of micro terminals and sensor pins with a minimal heat-affected zone, suitable for medical electronics and instrumentation.
Frequently Asked Questions
What industries is this ultrasonic welding machine mainly suitable for?
It is mainly suitable for industrial fields such as new energy vehicles (battery tab and busbar welding), high-voltage wiring harnesses (automotive/aerospace electrical connections), and large-section copper-aluminum terminal termination.
Is the 6000W power adjustable? Can it weld smaller or larger workpieces?
Power can be precisely adjusted via the digital control system, covering a welding area of 15-50mm². For welding smaller workpieces (e.g., 5mm²), it is recommended to select the 2000W or 4000W module; for larger workpieces (e.g., 70mm²), it can be upgraded to 8000W or 12000W power.
What daily maintenance does the equipment require?
Key maintenance includes: regularly cleaning the contact surface of the transducer and welding horn, checking the cooling system (if applicable), calibrating welding parameters, and tightening bolts. A comprehensive inspection is recommended every 5000 welds.
Can it weld dissimilar metals like copper and aluminum? How is the weld strength?
Yes. The equipment is optimized for copper-aluminum dissimilar metal welding, achieving atomic diffusion bonding between metals through high-frequency vibration. Weld strength can reach over 80% of the base material strength, with extremely low contact resistance.
Is installation and commissioning service provided after purchase?
We provide nationwide on-site installation and commissioning services, including operation training. For specific service details, please refer to the after-sales terms in the ultrasonic welding machine purchase considerations.
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.
Does ultrasonic welding generate noise? Are protective measures required?
The ultrasonic welding machine generates high-frequency pulsed noise of approximately 75~85 decibels at the moment of welding (0.1~1.0 seconds), similar to a short pneumatic hammering sound. The single pulse duration is short, and cumulative noise is low. It is recommended that operators wear noise-proof earplugs (NRR≥25dB), especially in high-frequency applications where a single machine performs more than 5,000 welds per day. A soundproof enclosure can be installed around the equipment, reducing noise by 10~15 decibels and meeting the factory occupational health standard of ≤85dB.
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.
Does the ultrasonic welding machine support automation integration and PLC control?
Yes. Yingna Technology ultrasonic welding machines provide RS232/RS485 communication interfaces and support integration with PLCs, robots, and automated production lines. Integrable functions: start signal, alarm feedback, welding parameter feedback, and production counting. With automatic wire feeding machines, automatic cutting machines, and automatic inspection equipment, a fully automatic ultrasonic welding production line can be built, requiring manual labor only for loading and unloading. Yingna Technology provides technical support to assist with automation solution design and installation and commissioning.
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.
How is the quality of ultrasonic welding judged and inspected?
① Visual inspection: qualified weld spots have clear, symmetrical patterns, with no cracks, porosity, or signs of overburning; ② Peel test: forcefully peel the welded area; a qualified weld should break in the base material rather than at the weld interface; ③ Resistance test: the resistance of the welded joint should be ≤100μΩ (measured with a micro-ohmmeter), and not higher than 10% of a wire of the same length; ④ Cross-section analysis: after metallographic cutting, the interface bonding rate should be observed to be ≥80%. Yingna Technology equipment can be integrated with automatic inspection systems to achieve online monitoring of welding quality.
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).
