3000W Automatic Wire Harness Welding Machine (Wire-to-Wire Welding)
Key Advantages | Intelligent Error Prevention & MES Integration
1. One-Click Recipe Recall for Quick Product Changeover
The unit stores up to 500 sets of welding recipes, allowing preset of process parameters for harnesses with different cross-sections, strand counts and materials.Switching between products is simple: just recall the saved recipe, and the system automatically adjusts welding width, energy, time and pressure. No repeated manual tuning is required, ensuring consistent welding quality and faster production changeover.It also supports parameter copying, import & export, and access permission management to prevent unintended changes to critical process settings.
2. Dual Error Alarm System for Full Quality Control
Equipped with high-precision position sensors, the machine provides dual protection.
Pre-welding alarm: It triggers an alert and locks operation if harnesses are placed reversed, skewed or mismatched, effectively preventing misplacement and wrong welding.
Post-welding inspection alarm: The system real-time monitors welding energy, power, depth, time and frequency. Once data exceeds the preset range, the machine alarms, stops running and marks defective products.It accurately identifies insufficient welding, over-welding, low voltage, frequency deviation, overload and overheating. With a 20ms rapid response, it protects both finished products and machine components.
3. Complete Data Logging & MES Connectivity for Full Traceability
Each welding operation automatically records the recipe number, timestamp, energy, power, travel distance, pass/fail status and operator information. Tens of thousands of production records can be saved locally for data inquiry, curve playback and statistical analysis.Built-in RS232 and Ethernet ports enable seamless connection with factory MES and ERP systems. It supports remote parameter distribution, automatic data upload, full quality traceability and remote equipment monitoring, fully meeting Industry 4.0 standards and customer quality audit requirements.
4. 3000W Optimized Power for Stable Welding of Small & Medium Harnesses
Designed specifically for wire-to-wire welding and parallel splicing of harnesses from 0.5 to 20 mm², the 3000W power output is perfectly matched to the application. It avoids excessive power and overheating issues.Supported by automatic frequency tracking and amplitude compensation, the machine delivers stable welding results. It causes no wire damage or insulation burn, and produces joints with excellent tensile strength.The fully automatic workflow — wire arranging, positioning, welding and discharging — reduces manual work and human errors, and greatly improves production efficiency.
