Manufacturer: Nippon Avionics Co., Ltd.
Model: SW-D10KH-20/SH-H10K

EV High-voltage cables are made of copper or aluminum materials and are directly bonded using ultrasonic metal-joining technology because joining of terminal and wire requires removal of oxide film on surface.
Moreover, not all kind of ultrasonic metal welders can join the target works unless the power is properly used, and the quality of the product will be affected such as cable breakage or lack of strength.

95SQ High-voltage cables

10 kW Ultrasonic Metal Welder is developed with a power output that is suitable for joining 95 SQ copper cables and 120 SQ aluminum cables

Even thick cables can be joined quickly with high accuracy.

This article introduces features and specifications of the SW-D10KH-20/SH-H10K 10kW ultrasonic metal welder for EV high-voltage cables.

Features of high-power ultrasonic metal welder “SW-D10KH-20／SH-H10K”

Joining time less than 2 seconds

With industry-leading 10,000W output power, 95SQ wire harnesses can be joined in less than 2 seconds*.
*Excluding cooling time

Run chart function for Predicting replacement schedule of horns and oscillators

Run chart function is equipped as standard which monitors joining result with time history.
Centralized monitoring of parameter values and external sensor values improves maintainability of the equipment.
It can also be used to predict when to replace horns and to detect signs of possible failure.

Saving joining result data and data output

Judgment Function

The SW-D10KH-20 ultrasonic generator is equipped with a comparison function that monitors oscillation frequency, oscillation time, peak power, etc. and compares them with upper and lower limit thresholds.
It can be used for OK/NG judgment and fault detection during production.

External IO interface for automated machine installation

To facilitate integration into an automated machine, an external IO input/output port is provided to monitor and control the status of the ultrasonic generator.

Control BOX UA-C02（Option）

It is used for setting generator (main unit setting such as joining conditions and IP address), software UPDATE, and saving settings to USB memory.

Features

• Intuitive operation：10.4” touch panel LCD (W640xH480)
• Connecting cable ：Standard 1.5m, extension cable 3.0m,5.0m,10.0m (Option)
• Hot Swap is supported
• Display: Japanese, English, Chinese are supported

Control BOX UA -C02

Model for automated machine installation

It consists of ultrasonic generator and oscillator.
The ultrasonic generator detects the start signal from outside and starts oscillation. Joining conditions and equipment settings can be set via RS-232C or Ethernet.
The optional control box UA C02 can also be connected to set the joining conditions and equipment setting

Ultrasonic Generator SW-D10KH-20 and Oscillator

Ultrasonic Generator Specifications

Items	SW-D10KH-20
Rated Output	10,000W
Frequency	20kHz
Power Supply Voltage	3-phase AC200Vー240V±10% 50/60Hz
Power Requirements	13,000VA
Oscillation Method	Digital Automatic Frequency Tracking Method (D-ATHMOS）
Oscillation Control Mode	Timer / Energy / Peak Power / Height / Depth / External Sensor / Continuous
Monitor Display	Oscillation frequency, Oscillation Time, Peak Power, Energy, Hight, Depth, External Sensor, Descending Speed, Pressure, Pneumatic Pressure ＊For external sensor display, unit of voltage, current, and temperature can be changed.
Display, Operation	Display on the main unit and on the control box
Interface	External IO×１, Analog IO×1, Emergency Stop Output ×2, Interlock×2, RS-232C×1, LAN×1, USB memory ×1
Operating Environmental Temperature	5℃～40℃ （No freezing）
Operating Environmental Humidity	Less than 85％ （No condensation）
Storage Environmental Temperature	-10℃～60℃
External Dimensions(mm)	W496ＸD558ＸH229mm（Including protrusions）
Weight	≒32kg

Ultrasonic Head Specifications

Items	SH-H10K
Pressure Method	Pneumatic cylinder
Min. Pressure	3,000N
Max. Pressure	10,000N
Length Measurement	Linear Scale (0.001mm resolution）
Required Pneumatic Source	Dry Air (0.6MPa)
Horn Strone	75mm
External Dimensions(mm)	W410xD665xＨ1045（Incluing Oscillator）
Weight	≒250kg

Control BOX UA-C02 Specifications

Items	UA-C02
Screen	Touch panel color LCD W640xH480 pixels
Operating Sound	Yes
Power Supply	Power supply from the generator
Cable Length	1.5m（Option：3m,5m,10m cable）
External Dimensions　(mm)	W283xD233xH52(Excluding protrusions）
Weight	≒2.0kg

EV High Voltage Cables Welding Machine SE-10K

Dedicated harness welding system incorporating 10kW ultrasonic metal welder SW-D10KH-20.

Features

• Number of joining condition registration: 31
• Recording and external output of production history
• Joining quality judgment function
• Monitoring function
  • Graphic display of monitor value
  • Run-chart display
• Language display: English, Japanese, Chinese

SE-10K Specifications

Item	SE-10K
Frequency (kHz)	20
Generator power (W)	10,000
Weld force max (N) at 6 bars	10,000
Stroke / Revision stroke	75mm
Outside dimensions incl. HMI operating cockpit (mm)	906(H)×1833(H)×1214(D) （Excluding protrusions）
Control panel (weld process control)	10.4“/7 ” Touchscreen
Operating modes	8
Application memories	31
Number of stored welds	100graphics/10,000,000data
Number of controllable auxiliary functions (optional)	3