Winna ultrasonic metal welding machine automation equipment customization, featuring high-precision servo control and military-grade quality certification, meet
Ultrasonic Metal Welding Machine Automation Equipment Customization is a core process equipment solution for new energy vehicles, energy storage systems, and high-end wire harness manufacturing. This product line covers multiple series from 3000W to 12000W across the full power range, and through precision welding control systems and automated integration interfaces, helps B2B manufacturing enterprises achieve efficient and reliable connections of dissimilar metals such as copper and aluminum, significantly improving welding consistency and production line yield rates.
In the manufacturing process of new energy vehicle power batteries, energy storage systems, and high-voltage wire harnesses, the process quality of copper/aluminum busbar connections and terminal welding directly determines the electrical conductivity and safety reliability of the product. Ultrasonic Metal Welding Machine Automation Equipment Customization achieves solid-state bonding between metal atoms through high-frequency mechanical vibration, requiring no solder or flux, fundamentally eliminating the cold solder joints, oxidation, and heat-affected zone issues present in traditional resistance welding. This customized solution can provide flexible configurations from single-machine semi-automatic to multi-station fully automatic integration according to different production line takt times, spatial layouts, and process standards, helping manufacturing enterprises establish a stable and traceable welding quality management system.
The core value of Ultrasonic Metal Welding Machine Automation Equipment Customization lies in its modular functional architecture and open system integration capabilities. The precision welding control system can monitor welding energy, amplitude, and time parameters in real time, ensuring each weld is completed within the optimal process window; the automation integration interface supports seamless connection with six-axis robotic arms, conveyor systems, and MES manufacturing execution systems, enabling real-time upload of welding data and remote download of process parameters. The data traceability and quality management module incorporates weld record storage and process recipe management functions, combined with remote diagnostic interfaces, shifting equipment maintenance from reactive response to proactive prevention. Safety protection and alarm mechanisms include overload protection, automatic frequency tracking, and fault self-diagnosis, ensuring equipment stability and safety during prolonged full-load operation.
For different welding cross-sectional areas and workpiece structures, we provide standardized models covering the full power range and support custom fixtures and tooling. The following are the key technical parameters of each main model:
| Model Number | Power Rating | Welding Area Range | Machine Weight | Dimensions (mm) | Typical Applications |
|---|---|---|---|---|---|
| YN-D2012-G | 12000W | 35-120mm² | 988KG | 1750×1050×2150 | Energy storage copper/aluminum busbar welding【（Fact 1）】【（Fact 9）】 |
| YN-D208-G | 8000W | 20-70mm² | 957KG | 1750×1050×2150 | Large wire harness copper/aluminum busbar welding【（Fact 2）】【（Fact 10）】 |
| YN-D206-G | 6000W | 15-50mm² | 192KG | 1400×760×2000 | High-voltage wire harness copper/aluminum terminal welding【（Fact 3）】【（Fact 11）】 |
| YN-X206-Z | 6000W | 10-50mm² | 118KG | 1020×610×1200 | Power battery wire harness welding【（Fact 5）】【（Fact 8）】 |
| YN-X204-Z | 4000W | 1-30mm² | 132KG | 1020×610×1200 | Lithium battery wire harness terminal welding【（Fact 6）】 |
| YN-X203-Y | 3000W | 0.35-20mm² | 88KG | 670×520×410 | High-precision metal welding【（Fact 7）】 |
| YN-P203-F | 3000W | 1-100mm² | 73KG | 565×269×442 | Precision electronics and sensor welding【（Fact 4）】 |
| JY-D204-F | 4000W | 1-35mm² | 82KG | 660×350×680 | Compact general-purpose welding【（Fact 12）】 |
YN-D2012-G, as the flagship model of the D series, covers a welding area of 35-120mm² with an ultra-high 12000W power output, specifically designed for energy storage system copper/aluminum busbar welding. The 988KG machine weight ensures rigid stability during the welding process. YN-D208-G and YN-D206-G meet the welding needs of large wire harnesses and high-voltage terminals with 8000W and 6000W power ratings respectively, with YN-D206-G adopting a split structure for flexible layout in limited production line spaces.
YN-X206-Z and YN-X204-Z optimize amplitude control algorithms for power battery wire harness welding scenarios, achieving stable welding quality within welding areas of 10-50mm² and 1-30mm². YN-X203-Y, with 3000W power and fine welding capability of 0.35-20mm², is certified with CE/FCC/ISO【（Fact 7）】and is suitable for applications requiring extremely high welding precision. YN-P203-F, with its wide welding area range of 1-100mm² and lightweight design of 73KG, becomes the ideal choice for precision electronics and sensor welding production lines.
Ultrasonic Metal Welding Machine Automation Equipment Customization has formed mature implementation practices in multiple industrial scenarios.In the field of new energy vehicle power battery wire harness and copper/aluminum busbar welding, fully automatic loading/unloading and welding operations are achieved through integration with six-axis robotic arms and visual positioning systems, with production line takt times reaching within 3 seconds per weld.In the scenario of large cross-section copper/aluminum busbar connections in energy storage systems, the YN-D2012-G model, combined with dedicated pressure tooling, ensures that the welding strength and electrical conductivity of 120mm²-class copper/aluminum busbars meet stringent industry standards.For high-voltage wire harness terminals and precision sensor welding, customized solutions provide floating weld heads and micro-pressure control functions, effectively preventing deformation and damage to thin-walled workpieces.
All customized solutions include non-standard fixture design based on customer workpiece shapes, welding areas, and production line takt times, ensuring the optimal balance between welding quality and production efficiency.
The full series of Ultrasonic Metal Welding Machines has passed international authoritative certifications including CE, FCC, and ISO【（Fact 7）】, with full-process quality control from factory inspection to on-site installation and commissioning. We provide customized training programs for each customer, covering equipment operation, process parameter adjustment, and daily maintenance; preventive maintenance plans are optimized based on equipment operating data, effectively reducing unplanned downtime. Critical components are managed with safety stock inventory to ensure rapid replacement response in case of failure. The equipment full lifecycle service commitment includes regular inspections, software upgrades, and process optimization support, ensuring long-term value of customer investment.
When selecting an Ultrasonic Metal Welding Machine Automation Equipment Customization solution, comprehensive consideration should be given to welding materials (copper or aluminum), cross-sectional area size, and workpiece structural characteristics. Generally, welding cross-sections below 20mm² can use the 3000W-4000W power rating; the 20-50mm² range is recommended to use the 6000W model; large cross-section welding above 50mm² requires the 8000W or 12000W power rating. Regarding production line automation level assessment, semi-automatic solutions are suitable for multi-variety small-batch production, fully automatic solutions are suitable for single-variety large-batch production, and multi-station integrated solutions are suitable for continuous operations in complex process chains. The customization cycle is typically 30-45 working days after contract confirmation, including on-site survey, technical solution confirmation, equipment manufacturing, and acceptance delivery.
Welding quality verification typically combines destructive tensile testing with metallographic cross-section analysis. We recommend customers conduct first-article full inspection before mass production, including tensile strength, electrical conductivity, and interface microstructure observation, and establish a quality database corresponding to process parameters.
Yes. The solid-state bonding mechanism of ultrasonic welding is naturally suited for copper-aluminum dissimilar metal welding, effectively suppressing excessive growth of intermetallic compounds, and the welded joint's electrical conductivity and mechanical strength are superior to traditional brazing methods.
Yes. The equipment comes standard with OPC UA and Modbus TCP communication protocols, enabling seamless integration with mainstream MES systems for real-time upload and traceability of welding parameters, production data, and quality records.
Based on customer's actual production line scale and welding volume, the ROI period for general automation customization solutions is between 12-24 months, with primary returns coming from improved yield rates, reduced labor costs, and increased production capacity.
The equipment can operate normally in conventional industrial environments with temperatures of 5-40°C and relative humidity not exceeding 90%, requiring no special foundation treatment, but it is recommended to install in areas without strong vibration interference to ensure welding precision.
Yes. We can customize weld head structures, horn sizes, and power matching solutions based on the customer's actual workpiece welding area requirements, supporting copper busbar welding above 200mm².
On-site operation training of no less than 2 working days is provided upon equipment delivery, covering equipment operation, parameter adjustment, daily maintenance, and common fault troubleshooting, with training covering both operators and equipment maintenance engineers.
The standard warranty period is 12 months, with key components (transducer, horn) provided with a 24-month warranty. After-sales service promises a 4-hour response to technical consultations and on-site arrival within 48 hours to resolve faults.
No. Ultrasonic metal welding is a purely solid-state connection process requiring no solder, flux, or shielding gas. The welding process is clean and environmentally friendly, compliant with RoHS and REACH regulations.
Yes. We provide multi-station integrated solutions with independent control modules enabling parallel welding at each station, improving overall production line efficiency by over 200%, suitable for high-volume standardized production scenarios.
The equipment has a built-in process recipe management function that can store up to 100 sets of welding parameter recipes. For new workpieces, we provide process testing services, determining optimal parameter combinations through DOE experimental design methods.
Taking YN-D206-G as an example, rated power consumption is approximately 8kVA, with standby power consumption below 0.5kW. Compared to resistance welding equipment, ultrasonic welding reduces energy consumption by approximately 80%, offering significant energy-saving advantages.
The weld head is made of imported alloy steel and can achieve a service life of over 100,000 cycles under standard operating conditions. Replacement costs vary by model, approximately 3%-5% of the total equipment price. We recommend customers stock a spare weld head to ensure continuous production.
Yes. The equipment has a built-in remote diagnostic module. With customer authorization, our technical personnel can remotely view equipment operating status, read fault logs, and perform parameter optimization adjustments via the network.
The delivery cycle for standard models is 15-20 working days, and for customized solutions (including non-standard fixtures and automation integration) is 30-45 working days, depending on the complexity of the solution.
Yes. The core components of the equipment are designed to industrial-grade standards, with the cooling system combining independent air cooling and water cooling, capable of meeting 24-hour continuous full-load production requirements.
Winna Technology specializes in power adapters, AC/DC cable harness customization, and ultrasonic metal welding equipment R&D and manufacturing, providing one-stop OEM/ODM services.
Our products are CE/UL/FCC/CCC/RoHS certified, with an annual return rate below 0.02%, serving customers in 50+ countries and regions worldwide.
Products meet international safety and EMC standards
