Wiring Harness News Sep-Oct 2022 - Page 44


Understanding PowerWheel ® for EV Cable Terminations

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PowerWheel ® Welding Technology for Terminating Stranded Wire - Actual Application Cases :
1 . Small weld width without damage to fine cable strands
Figure 3 . ProEVTM cable , produced by Promark Electronics a Division of ECI , welded to a Rosenberger male Silver-plated connector .
In the application shown in figure 3 , a high quality 35 mm2 ProEVTM cable is welded to a Rosenberger connector , which supplies limited space for a cable of that size . ProEVTM cable was selected for this application due to its high flexibility . However , the available weld width of 10 mm as opposed to 11 mm and flexible finer strands presented some challenges . A solution that could provide a weld on a smaller space where the required weld compaction can be achieved without damages to the finer strands in the weld transition area was needed .
Solution :
The torsional PowerWheel ® welding technology system was utilized to achieve a superior quality weld between the flexible ProEVTM 35 mm2 cable and the connector with 10 mm width . Tooling design and configuration had to be arranged to compensate for the limited clamping force due to the inherited connector radius . This tooling design and configuration solution allowed for sufficient welding energy to achieve a quality weld .
2 . Weld area is out of reach
The terminal blade width for 50 mm ² was changed to 18 mm from 13 mm to accommodate a weld width of 15 mm . This also allows for 1.5 mm of clamping width on each side of the terminal when utilizing a 15 mm sonotrode . However , the connector height of about 17 mm presented a challenge for the sonotrode ’ s clearance in conventional longitudinal ultrasonic welding processes . It is not physically possible to design a linear sonotrode that can clear the 17 mm height and still efficiently deliver the 20 kHz . frequency required .
Solution :
The torsional PowerWheel ® system was utilized to clear the connector height and achieve a superior quality weld for both 35 mm ² and 50 mm2 cables with the SQ4 terminal . The sonotrode ’ s orientation allows for the clearance with the 90 ° terminal and delivers sufficient welding energy to achieve a quality weld without effecting the finer strands in the transitional area or the connector itself due to the gentler application of the vibrations .
3 . More examples of challenging applications ( Figure 5 ).
The following represent some additional applications and challenges in the ultrasonic welding of terminals on stranded wire that the Telsonic PowerWheel ® system can address :
Figure 4 . 90 ° SQ4 terminal welded to a 50 mm2 cable .
1 . High voltage cable set with tubular cable lugs - Welding is proven to work with PowerWheel ® .
The 90 ° SQ4 terminal , shown In figure 4 , is made of C15100 Copper alloy without pla plating in the weld area . This application required welding both 35 mm ² and 50 mm ² cables .
2 . Shielded cables - larger cables up to 200 mm ² in a smaller weld area is possible when there are restrictions on surface area of the connector .
3 . Short cables welded on both sides - Welding both ends of a short