20KHZ Automatic Ultrasonic Wire Splicer For Wiring Harness Welding With PLC

20KHZ Automatic Ultrasonic Wire Splicer For Wiring Harness Welding With PLC

Ultrasonic wire splicer with PLC



Bonne’s 20 kHz ultrasonic wire splicing machine provides a wide range of configurations for copper wire welding. Each configuration is optimized and improved for research and development.

The Ultrasonic wire splicer contains three operating modes: manual operation, touchscreen operation, or full automation. The standard version can be used for aluminum foil welding and wire processing.


Advantages of Ultrasonic Wire Welding

1. Faster welding and safety. 

2 No acid, no solder, easy to operate.

3. High strength. up to 80% strength of the original copper wires.

4. Cold welding, no change in the metal’s resistance.

5. The PLC control system can track each time welding data.

6. Up to 70-95mm square copper wire welding.


Parameters of Bonne’s ultrasonic wire splicer for wiring harness

Product Model Power working frequency weld area working pressure voltage weight size(mm)
wire welder
X2020C 2kw 20khz 0.35-14mm² 0.05-0.9Mpa 220v 40kg 520*180*200
X2030A 3kw 20khz 0.35-20mm² 0.05-0.7Mpa 220v 37kg 560*220*240
X2030B 3kw 20khz 0.35-20mm² 0.05-0.7Mpa 220v 40kg 560*220*240
X2040A 4kw 20khz 0.35-30mm² 0.05-0.9Mpa 220v 37kg 560*180*220
X2040B 4kw 20khz 0.5-30mm² 0.05-0.9Mpa 220v 40kg 560*180*220
X2040C 4kw 20khz 0.5-35mm² 0.05-0.9Mpa 380v 40kg 560*180*220


Ultrasonic wire splicer is suitable for welding copper and aluminum wire harnesses, automotive connector wire harnesses, and ultrasonic welding of copper wires such as wire harness terminals, enameled wires, motor lead wires and wiring harnesses, and aluminum wires.

The 20kHz ultrasonic wire splicer has found widespread use in automotive wire harness production plants, particularly with the growing demand for new energy vehicles.
The ultrasonic wire splicer is well-suited for soldering copper wires, which is a common material in automotive wiring harnesses due to its excellent conductivity, making the ultrasonic wire splicer a crucial tool in the manufacturing process.

If you have products that need to be welded, please inquire, our company provides free proofing services.


Samples of Copper Wire Welding

Main Components of Ultrasonic Wire Splicer


The primary function of a generator in the ultrasonic wire splicer is to convert electrical energy into mechanical or kinetic energy.
It produces the high-frequency electrical signal that powers the transducer. The frequency typically ranges up to 20 kHz.



The transducer is responsible for converting the high-frequency electrical signal generated by the generator into mechanical vibrations.

The transducer plays a pivotal role in delivering this vibrational energy to the welding head, facilitating the welding process.

Welding Head

The welding head is the part of the ultrasonic wire splicer that comes into direct contact with the materials being joined.

The welding head is designed to frictionally contact the materials, creating localized heat and promoting the welding process.

Controller (PLC – Programmable Logic Controller)

The controller, often implemented as a touch screen control panel with a programmable logic controller (PLC), serves as the brain of the ultrasonic wire splicer.

The touch screen interface allows operators to set and control various parameters such as welding time, pressure, and amplitude.
The PLC manages and coordinates the operation of different components, ensuring precise control and repeatability in the welding process.

Additionally, the controller may include features like data logging, error detection, and other advanced functionalities to enhance the overall efficiency and reliability of the ultrasonic wire splicer.



Q1: What are ultrasonic wire splicer and ultrasonic wire harness welding technology?

Ultrasonic wire harness welding technology uses 20,000 frictions per second to fuse the atoms inside the metal to achieve the purpose of welding. It is a type of cold welding. At this stage, it is only suitable for welding cold metals such as copper, aluminum, and silver.

Q2: Is ultrasonic wire harness welding safe?

There are no risks in ultrasonic wire harness welding. However, be careful not to touch the workpiece, welding head and surrounding components with your hands just after welding, because the heat generated by friction will make the welding spot very hot.

Q3: What thickness of metal is usually restricted for wire harness welding?

Materials with a thickness within 2cm can be welded. The welding equipment produced by Bonne can currently weld up to 95mm sq, and the effect is stable and can be mass-produced.

Q4: Why use 20kHz ultrasonic wire splicer for automotive wire harness production?

Here are the reasons to use 20kHz ultrasonic wire splicer for automotive wire harness production:

Cold Welding Technology: The 20kHz ultrasonic wire splicer utilizes high-frequency friction for welding without generating heat, a process known as cold welding. This is especially beneficial for sensitive materials like copper, as it avoids any burning or direct high-temperature impact on the wires. Compared with traditional welding methods(such as those involving heat), the use of ultrasonic wire splicer avoids damage to wire harness products during the production process to a large extent, ensuring the product quality of automotive wire harness manufacturers.

High-Frequency Friction: The ultrasonic wire splicer operates by rapidly rubbing or vibrating at a frequency of 20,000 times per second. This high-frequency friction causes metal molecules to fuse, achieving a strong weld between the wires without the need for additional heat sources.

Improved Production Efficiency: The precise control offered by the touch screen interface and programmable logic controller (PLC) in the ultrasonic wire splicer contributes to enhanced production efficiency. Operators can set and adjust parameters with ease, leading to consistent and reliable wire splicing.

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