Automotive Electronic Harness Welding, Using Resistance Welding Equipment

Principle of Resistance Welding

Resistance welding is a method in which the workpieces to be welded are tightly pressed between two electrodes and an electric current is passed through. It utilizes the resistance heat generated when the current flows through the contact surface of the workpieces and the adjacent areas, heating the contact surface of the workpieces to a molten or plastic state to form a metallic bond. Simply put, it is a welding process where metals are fused together by the resistance heat generated through the passage of electric current, as shown in the following diagram:

Resistance Welding Mode Diagram

Advantages of Resistance Welding:

1. Short welding time, high efficiency, concentrated heat, and no need for additional post-treatment processes.
2. Low cost, with no requirement for other auxiliary materials.
3. Simple operation, easy to realize automation and integration into production lines.

Therefore, it is widely used in various industrial sectors such as aerospace, energy, electronics, automotive, and light industry, and is one of the important welding processes.

Our company uses two types of wire harness welding power supplies: high-frequency inverter inverter welding power supplies and medium-frequency inverter welding power supplies.

Features of high-frequency inverter DC welding power supplies:

1. Intuitive LCD display for convenient operation.
2. DC output with good thermal efficiency, energy saving and consumption reduction, and stable output; inverter frequency of 4KHZ or 1KHZ, with arbitrarily controllable welding time.
3. Equipped with constant voltage, constant power, constant current, and fixed pulse width mode control; which can greatly reduce the defective rate of product welding.
4. Three-band current setting with current slow rise and slow fall control, which can effectively solve splashing, further ensuring welding stability and effectively extending electrode life.
5. Complete external communication functions, suitable for cooperation with various special machines and automated production lines.