Fully Automated Frequency-Tracking Ultrasonic Welding Machine for EV & Motorcycle Wiring Applications

Product Description

Product Description

KK-4000  Ultrasonic Wire Harness Welder | for 2-22mm² Cables

The KK-4000 is a 4000W ultrasonic press welder with a 7-inch touchscreen. It creates solderless, spark-free bonds for copper/aluminum wires 2-22mm². Features auto frequency tracking, weld data logging, and is ideal for automotive harness production.

This machine is an all-in-one solution designed to streamline your wire harness production. It performs three critical functions seamlessly:

Precision Stripping: Cleanly removes insulation.
Ultrasonic Solid-State Welding: Bonds wires without solder, sparks, or fumes, creating a superior electrical and mechanical connection.
Terminal Forming: Compresses the welded bundle into a dense, square terminal ready for assembly.
Ideal for processing wires from 2mm² to 22mm², it replaces multiple separate processes, boosting efficiency and consistency in automotive and industrial harness manufacturing.

Specification

Parameter	Specification
Model	KK-4000
Power Supply	AC 175-250V, 50/60 Hz
Welding Range	2 – 22 mm² (Copper / Aluminum wires & bundles)
Output Power	4000 W
Frequency	20 KHz
Weight	50kg
Display	7-inch Touchscreen
Key Feature	Automatic Frequency Tracking & Weld Record Query
Applied field	Automotive & Motorcycle Wire Harnesses, Welding of multi-strand cables, wire-to-wire joints, Forming wires into compact, square terminals (custom anvil available)
Fumction	Integrates wire stripping, terminal crimping, and ultrasonic welding in one process:Wire-to-Wire Welding,Harness Forming,

Product details

Processed samples

Company Profile

Packing & Delivery

FAQ

Q1: What are the core technical features of your machines?
A: 

Key features ensuring reliability include:

Auto Frequency Tracking: Maintains optimal resonance automatically, even when changing horns.
Precision Linear Guides: Guarantees consistent, vertical pressing force for uniform weld quality.
Intelligent Control: User-friendly touchscreen (EN/CN) for parameter setting, storage, and recall.
Robust Safety Protections: Built-in safeguards against over-current, over-voltage, and phase loss.

Q2: Which model should I choose for different welding wires?
A: 

We offer models for different capacities:

KK-2020 (2000W): For precision harnesses, 0.5 - 8 mm².
KK-2040 (4000W): For mainstream automotive wires, 2 - 22 mm².
KK-2080 (8000W): For heavy-duty cables/busbars, up to ~75 mm².
Our sales engineers can recommend the optimal model based on your exact wire specs and output goals.

Q3: How does ultrasonic welding differ from soldering or resistance welding?
A: 

It's a cold, solid-state process with key advantages:

No Consumables: Requires no solder/flux, creating a pure metal bond with minimal resistance.
No Melting: Joins metals below their melting point via friction, preventing brittle joints.
Clean & Efficient: Produces no sparks, minimal fumes, and uses less energy than resistance welding.
Highly Automatable: Ideal for integration into automated production lines.

Q4: How do you ensure consistent weld quality?
A: 

Quality is ensured through:

Process Validation: Free sample welding tests are available before order confirmation.
Process Monitoring: Real-time display of key parameters (energy, time, pressure); optional crash detection and alarm.
Stable Components: Use of branded power supplies and pneumatic parts ensures long-term reliability.