Wiring Harness News Sep-Oct 2022 - Page 36

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Understanding PowerWheel ® for EV Cable Terminations

By Saeed Mogadam Telsonic Solutions ___________________________

Ultrasonic welding of nonferrous metals has been a proven technology for decades . However , since the early 1980 ’ s , ultrasonic metal welding has dominated the automotive industry , with automotive wire harness manufacturers as the single largest user of the technology . Due to its efficiency and unbeatable quality , ultrasonic welding replaced mechanical crimping and resistance welding for all car brands almost immediately upon inception . The utilization of ultrasonic welding for automotive wire harnesses has seen even more rapid growth in the last decade due to the increase in electrically powered vehicles ( EV ). Telsonic ’ s innovative and industry changing torsional welding technique has in large part contributed to this rapid growth due to its unrivalled ability to address challenges such as weld size , welding in smaller areas , geometrical shapes , reaching the weld area , orientation of welding , and vibration effects on peripheral components .

Telsonic ’ s Torsional welding technique has overcome many of the current limitations in longitudinal welding and has created breakthrough applications that were previously considered impossible or not up to quality standards prior to last decade . Now , the technology is increasingly specified by carmakers for use in EV for weight control , battery packaging , cable to terminal connections , bus bars , battery manufacturing and power electronics . The higher power and faster charging of EV batteries requires larger battery cables with , sometimes , unconventional connectors . Telsonic ’ s PowerWheel ® welding technology , which utilizes torsional welding , provides a solid assembly solution that satisfies the high-quality requirements in the Automotive industry .
Challenges of Longitudinal Welding with Larger Cables
There are several obstacles one needs to overcome when welding larger cables . These can include :
1 . The larger the weld width , the better the transfer of vibrating energy to join the cable and the connector . However , as there are limitations for the connector , there are also limitations on how large the sonotrode ( vibrating tool ) can be . In addition , the wider the weld width is , the more nicking of the strands can occur at the transition area of the weld . The connector ’ s surface area , geometrical

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