Advantages of Ultrasonic Welding over Crimping in EV Charging Cables Manufacturing

 

As the demand for electric vehicles (EVs) continues to surge, so does the need for reliable and efficient charging infrastructure. Fiver New Energy Co.,ltd, as a EV charging cable manufacturer, we're at the forefront of providing essential infrastructure for the growing electric vehicle market. Our commitment to quality, innovation, and sustainability drives us to deliver products that exceed industry standards and meet the evolving needs of EV owners and operators. With a focus on high-power charging solutions, we're empowering the transition to electric transportation by ensuring that drivers have access to fast and reliable charging options.

What is Ultrasonic Welding?

Ultrasonic welding technology is a non-destructive joining process that uses high-frequency sound waves to bond materials together. In this method, a transducer converts electrical energy into mechanical vibrations, which are then transmitted to the materials being joined. These vibrations cause the molecules in the materials to rub against each other, generating heat and melting the surfaces. As the surfaces cool, they bond together, forming a strong and durable joint.

 

Advantages of Terminal Ultrasonic Welding Technology in EV Charging Cable Manufacturing:

Terminal ultrasonic welding is increasingly being adopted in the manufacturing of EV charging cables due to several distinct advantages over traditional crimping technology:

1. Improved Electrical Conductivity:

  • Cleaner Joint: The high-frequency vibrations created during ultrasonic welding can scrub away microscopic impurities and contaminants from the surfaces being joined, creates a cleaner and more consistent joint between terminals and cables,  and compared to crimping, which can leave behind indentations or burrs that can interfere with electrical conductivity.

  • Reduced Contact Resistance: The ultrasonic vibrations can cause slight deformations in the materials, creating a more intimate contact between High power EV charging cables's conductor and terminals. This increased contact area reduces the resistance. what's more during the ultrasonic welding process heat is generated, the heat can be sufficient to melt the surface layers of the materials being joined. This melting process can create a more homogenous interface, further reducing contact resistance. For EV charging cables for high power charging, minimizing contact resistance is paramount to preventing excessive temperature rise. This is especially crucial for electric vehicles (EVs) that require rapid charging to meet the demands of daily use.

2. Enhanced Mechanical Strength:

  • Stronger Joint: Terminal ultrasonic welding produces a stronger and more durable joint than crimping, which can sometimes result in weaker connections, especially under repeated stress and vibration.
  • Reduced Risk of Failure: The enhanced mechanical strength of ultrasonic welded joints helps to prevent cable failures and ensures the reliability of EV charging cables.

3. Improved Durability:

  • Resistance to Corrosion: Ultrasonic welding creates a more uniform and corrosion-resistant joint compared to crimping, which can leave gaps or crevices where moisture can penetrate and lead to corrosion.
  • Longer Lifespan: The improved durability of ultrasonic welded joints contributes to a longer lifespan for EV charging cables.

4. Increased Efficiency:

  • Faster Production: Ultrasonic welding is a faster process than crimping, allowing for higher production volumes and reduced manufacturing costs. the adopting of this ultrasonic welding technology allows Fiver to supply our customers with higher quality high amperage EV charging cables in a shorter time.
  • Reduced Waste: Ultrasonic welding can minimize material waste by creating more precise and efficient connections, leading to cost savings.

5. Better Aesthetics:

  • Neater Appearance: Ultrasonic welded joints typically have a neater and more aesthetically pleasing appearance compared to crimped joints, which can be bulky or uneven.
  • Improved Product Quality: A better-looking product can enhance customer perception and satisfaction.

Terminal ultrasonic welding offers several significant advantages over traditional crimping technology in the manufacturing of EV charging cables. These advantages include improved electrical conductivity, mechanical strength, durability, efficiency, and aesthetics. As an EV charging cable manufacturer, Fiver New Energy Co.,ltd have applied the terminal ultrasonic welding technology in our daily production of the CCS1 charging cables, CCS2 charging cables, NACS charging cables, GBT Charging cables over 200A.

 

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