New Energy High-Voltage Harness Terminal Welding | Electric Vehicle Busbar Connection
2026-08-05 00:00:00
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Process Overview
Ultrasonic high-voltage harness terminal welding joins orange EV high-voltage cables to copper or silver-plated copper terminals. The solid-state joint replaces traditional bolted or crimped connections, reducing contact resistance and improving connection reliability.
Process Specifications
| Welding type | EV high-voltage harness terminal welding |
|---|---|
| Frequency | 15 kHz |
| Welding power | 4,000–6,000 W |
| Welding time | 0.4–0.8 s |
| Amplitude | 60–90 μm |
| Cable range | 16–120 mm² stranded copper-core EV high-voltage cable |
| Terminals | Copper or silver-plated copper terminals for 8–16 mm bolts |
| Tensile strength | ≥ the cable body strength |
| Contact resistance | ≤10 μΩ |
| Thermal cycling | Less than 3% degradation after 200 cycles |
Process Advantages
Ultrasonic welding creates a molecular-level metallic bond without an added contact interface. This removes the looseness and oxidation risks that increase resistance in crimped or bolted joints.
The process produces no sparks or welding fumes and meets the cleanliness requirements of EV harness production lines. Samples pass QC/T 1067.1 and ISO 6722 automotive harness tests.
Typical Applications
- Power-battery high-voltage busbar connections
- Three-phase cables for motor controllers
- Internal busbars in power distribution units
- Charging-socket high-voltage harnesses
Sample Images
The gallery images show actual high-voltage harness terminal welding samples.