20kHz 3000W Ultrasonic Wire Harness & Battery Terminal Metal Welder (UL-MW3000)
The UltraLanank UL-MW3000 Ultrasonic Metal Welder (20kHz 3000W) is an industrial non-ferrous metal bonding workstation designed for automotive wiring harness splicing, electric vehicle (EV) battery foil welding, and copper/aluminum terminal crimping. Operating without solder, flux, or protective gas, it produces high-conductivity atomic diffusion joints with negligible electrical resistance.
Key Technological Advantages
- Atomic Diffusion Solid-State Joint: Welds non-ferrous metals (Cu, Al, Ni, Au, Ag) below melting points, eliminating metallurgical brittleness and thermal oxidation.
- Intelligent Energy Welding Mode: Precision energy, time, and absolute collapse depth controls guarantee consistent weld nugget cross-sections across wire splices up to 45 mm².
- Hardened High-Wear Tooling: Textured welding anvils and sonotrodes manufactured from premium imported powder metallurgy steel for extended duty cycles exceeding 500,000 welds.
- Integrated Quality Control: Real-time dynamic impedance and amplitude regulation with instantaneous upper/lower limit error interlocks.
Technical Specifications
| Parameter | Specification |
|---|---|
| Operating Frequency | 20 kHz (Continuous Auto-Tracking) |
| Maximum Power Output | 3000 W (Peak 3500 W) |
| Welding Capacity (Wire Harness) | 0.5 mm² to 45 mm² (Copper / Aluminum) |
| Air Pressure Required | 0.4 – 0.8 MPa |
| Welding Modes | Time Mode, Energy Mode, Height / Depth Mode |
| Input Voltage | AC 220V ±10%, 50/60Hz, 16A |
| Actuator Weight | Approx. 45 kg (Benchtop mountable) |
Typical Applications
Automotive electrical harnesses, lithium battery current collector foil tabs (multi-layer copper/aluminum foils to busbars), solar panel junction ribbons, and relay contact rivets.
Complimentary Metal Welding & Pull-Force Testing
Send wire bundles or battery foil samples to our laboratory for trial ultrasonic welding. We provide micro-resistance measurements, peel/shear tensile pull tests, and video documentation.
Engineering Feasibility & Free Lab Testing
Need custom horn tooling or joint validation? Send your 2D/3D CAD models (.STEP, .DWG) or molded parts to our Dongguan R&D lab for free test welding and weld strength reports.
- 12-Month Global Warranty: Full machine parts replacement & lifetime engineering support.
- Custom CNC Tooling: In-house CNC titanium (TC4) & aerospace aluminum horns machined to 3D CAD.
- Free Sample Welding Trial: Feasibility report, tensile pull data, and 4K welding video within 48h.
- CE & ISO 9001 Certified: 100% pre-shipment load aging & export wooden-crate packaging.