Automatic Square Compaction Welding Machine for Wire Harness Cable and Copper Braid End

Wire Harness Square Compaction Machine: Cable, Braid And Terminal Ends Formed Solid In One Press

Application story  ·  Resistance-heated square compaction of wire harness ends, copper braid and terminals

One job, done at production speed: a stripped cable end or a copper braid end goes into the fixture, the fixture clamps, the ram presses and the strands are consolidated into a solid square block. The operator loads the part and presses start - nothing else.

The cell: press head, clamp fixture and HMI on the left frame; the separate water chiller on the right

One Button, One Solid Square End

The operator lays the stripped end into the lower die. The start signal closes the clamp, the upper electrode comes down, current passes through the bundle and the copper is pressed into a block with a square or rectangular section. The ram lifts, the clamp opens, the part comes out - no filler metal, no flux, and no operator skill beyond loading the part the right way round.

A compacted end behaves like a machined part. The strands can no longer spread, the section is flat enough to sit on a busbar or a terminal, and the block can be drilled, tapped, bolted or brazed in the next operation. Because every part leaves the die at the same height and width, downstream assembly stops needing a selection step.

Inside the working area: upper copper electrode on the ram, electrode block below, and the two clamp jaws that square the end before the current is switched on

MFDC Heating Keeps The Dimension

The welding power source is a medium-frequency inverter DC unit. Discharge time is short, current rise is fast and the output is direct current, so the heat is concentrated in the compaction zone instead of running up the insulation. The pressed block holds its dimension after cooling - no collapsed edge, no oval section - and the same schedule repeats part after part. That is where the yield comes from: the die fixes the shape, the power source only has to deliver the same heat every cycle.

Water runs through the electrodes and the die block, supplied by a chiller that stands on its own castors. Heat stays out of the press frame and the schedule does not drift in the middle of a long shift.

Front view: press head and clamp fixture behind the guard, with the HMI that stores the welding schedule

One Operator Loads And Unloads

The fixture does the clamping, not the operator. Loading and unloading both happen at the front of the machine, so one person runs the cell: load, press, take out, next part. There is no second operator behind the machine and no manual clamping step to slow the cycle down. Starting can be a push button on the fixture or a foot switch, whichever suits the way the cell is laid out.

The working area is closed by an aluminium-frame guard with transparent doors, and the press head carries an anti-crush warning. The emergency stop sits within reach of the operator's hands.

What The Machine Forms

One cell covers a family of parts rather than a single terminal. Every sample below came off the same machine:

· Cable ends, 25 / 35 / 50 / 70 mm², compacted to a solid square block

· Copper braid ends, same four sections, braid fully consolidated

· Silver-plated copper braid, plating intact after compaction

· Multi-strand cable and enamelled wire ends

· Multi-strand silver-plated braid

· Copper cable and braid terminals, brazed, spot-welded or square-crimped

Sample set produced on this cell: 25 to 70 mm² cable and copper braid, plus brazed, spot-welded and square-crimped terminals

Block size is set by the die, and the welding schedule is stored in the control. A new part therefore means a new die set and a new schedule, not a new machine - the same frame, power source and control cover a 25 mm² cable end and a 70 mm² braid end, and the customer's next part is one die change away.

Where It Runs

The cell is delivered as two pieces: the press with its fixture and control on one frame, and the chiller on its own castors. The chiller can stand beside the machine or under the bench, so the cell drops into an existing line without a plant cooling-water installation.

· EV and automotive wire harness plants

· Power battery pack and energy storage busbar / flexible connection assembly

· Motor and electrical appliance lead forming

· Charging gun and high-voltage connector cable ends

· Copper braid flexible connectors for switchgear, inverters and busbars

Key Specifications

How A Custom Cell Is Built

01   Part drawing and sample review

02   Compaction trial on our own press

03   Process proposal and quotation

04   Die and electrode design in 3D

05   Manufacturing and in-house run-off

06   Installation and operator training

07   Pre-acceptance run at the customer plant

08   Final acceptance and volume production

09   After-sales service and spare dies

Talk to Pudian Technology

Guangdong Pudian Automation Technology Co., Ltd builds custom welding and forming cells in-house: fixtures, electrodes and dies, feeding, welding and inspection - one team, one solution. Send us a cable end or a braid end and we will return a compaction sample with the section measured.