TP-WA90 and the TP-W120 Ultrasonic Wire Harness Welder – Intelligent, High‑Speed, and Precision‑Controlled
They are one of our flagship ultrasonic metal welding machines, engineered specifically for large‑cross‑section wire harnesses, including automotive and motorcycle cable assemblies, as well as copper‑to‑aluminum splicing. With a robust design and precision manufacturing, this system delivers exceptional welding performance, consistent joint quality, and long‑term reliability.
Key Applications: Automotive wire harnesses, Motorcycle wire harnesses and Other cable assemblies (copper, aluminum, and dissimilar metals)

Features:

• Versatility – handles max 90 and120 mm² large conductors, ideal for EV battery packs, heavy‑duty cable splicing, and busbar terminations.
• Self‑developed PC‑based control software (Windows 10 interface) and proprietary control board – offering multiple welding modes to suit diverse production needs.
• Data‑Driven – real‑time monitoring and MES connectivity enable predictive maintenance and zero‑defect strategies.
• Password protection & parameter traceability – supports QR code / barcode scanning for full process documentation and lot tracking.
• The welding time less than 1 second, combined with intelligent process control, to significantly boost throughput and part quality.
• Proprietary compensation algorithm – automatically adjusts for horn wear, ensuring consistent height parameters throughout the electrode life, eliminating manual recalibration.
• High‑precision distance sensor – provides real‑time, closed‑loop control of weld height and distance, guaranteeing micron‑level accuracy for every joint.
• Upgraded power control cabinet – captures rich real‑time welding data (energy, power, displacement, force, etc.) for comprehensive quality monitoring.
• The system seamlessly integrates with MES (Manufacturing Execution System) for full production traceability.