Cases

High-voltage wire harness welding often suffers from insufficient joint strength. Traditional crimping or fusion welding processes are inefficient and may cause environmental contamination. Multiple processing steps are scattered across different stages, making system integration difficult. These limitations make it challenging to meet automotive-grade mass production requirements and prevent production data traceability.

Liquid-cooled ultra-fast charging guns and GB-standard DC charging guns require high-current transmission. Traditional processes often lead to high contact resistance, poor heat dissipation, and insufficient fatigue resistance. In addition, the wire harness processing procedures for charging guns are complex and inefficient, making it difficult to meet large-scale production demands. Products must also pass certifications such as high-voltage and waterproof standards.

Wire harnesses used in industrial controllers and servo motors are typically produced in multi-variety, small-batch production, resulting in high changeover costs and low production efficiency. High welding precision is required to ensure stable signal transmission while controlling manufacturing costs and improving automation levels.

Energy storage PACK wire harnesses and PCS (Power Conversion System) high-voltage harnesses must withstand extremely high current (1000A+) and high voltage (1500V). This places very high demands on joint strength, heat dissipation performance, and fire safety. Traditional processes often result in unstable joints and shorter service life, making it difficult to meet the 10+ year lifespan requirement of energy storage systems. In addition, achieving production data traceability remains a challenge.

Aerospace wire harnesses must meet strict requirements for lightweight design and high reliability, while being able to operate in extreme environments such as vacuum and extreme temperatures. Welding precision requirements are extremely high. Traditional processes may damage wire cores and are difficult to adapt to lightweight materials, making it challenging to meet aerospace-grade reliability standards.

Wire harnesses used in medical equipment must meet strict sterility and contamination-free requirements, where connection safety and stability are critical. Due to the small and delicate structure of medical wire harnesses, welding is highly challenging. Traditional processes may introduce impurities, making it difficult to pass medical industry certifications and ensure the safe operation of medical equipment.