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TP-WA90 TP-WA120
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Description
The TP-WA90 and TP-WA120 ultrasonic wire harness welders represent one of our flagship ultrasonic metal welding systems, engineered specifically for large-cross-section wire harnesses — including automotive and motorcycle cable assemblies, as well as copper-to-aluminum dissimilar metal splicing. With robust construction and precision manufacturing, this series delivers exceptional welding performance, consistent joint quality, and long-term operational reliability.
Key Applications:
Automotive wire harnesses
Motorcycle wire harnesses
Cable assemblies (copper, aluminum, and dissimilar metals)
Key Features:
High Capacity – Handles up to 90 mm² (TP-WA90) and 120 mm² (TP-WA120) large conductors, ideal for EV battery packs, heavy-duty cable splicing, and busbar terminations.
Intelligent Control System – Self-developed PC-based control software (Windows 10 interface) with proprietary control board, offering multiple welding modes to suit diverse production requirements.
Data-Driven Production – Real-time monitoring with MES connectivity enables predictive maintenance and supports zero-defect quality strategies.
Process Traceability – Password protection and parameter logging; supports QR code / barcode scanning for full process documentation and lot tracking.
Ultra-Fast Welding – Welding cycle under 1 second, combined with intelligent process control, significantly boosting throughput and part quality.
Automatic Wear Compensation – Proprietary compensation algorithm automatically adjusts for horn wear, ensuring consistent welding height throughout electrode life — eliminating manual recalibration.
High-Precision Distance Sensor – Provides real-time closed-loop control of weld height and distance, guaranteeing micron-level accuracy for every joint.
Comprehensive Data Capture – Upgraded power control cabinet captures rich real-time welding data (energy, power, displacement, force, etc.) for complete quality monitoring.
MES Integration – Seamlessly connects with Manufacturing Execution Systems for full production traceability.
Model | TP-WA90 | TP-WA120 |
Welding range | 10mm-90mm sqmm | 20mm-120mm sqmm |
Power | 9000w | 15000W |
Stroke | 40mm | |
Filtration accuracy | 5μm | |
Operating temperature | +5°C-50°C | |
Operating humidity | 30%~95% | |
System available stroke | Internal adjustable | |
System descent speed | 8mm/s~100mm/s | |
Operating voltage | 380V AC | |
Air connection | 0.55MPa~0.65MPa | |
Overall dimensions | 1200 x 900 x 1400(mm) | |
Frame weight | 320KG | 340KG |
The TP-WA90 and TP-WA120 are high-power ultrasonic wire harness welders for large-cross-section conductors including automotive/motorcycle cable assemblies and copper-to-aluminum dissimilar metal splicing.
TP-WA90: 10-90mm², 9000W. TP-WA120: 20-120mm², 15000W. Both feature 40mm stroke, 8-100mm/s descent speed, 0.55-0.65MPa air, and operate on 380V AC.
Key features include PC-based control with Windows 10 interface, welding cycles under 1 second, automatic wear compensation for consistent weld height, high-precision distance sensor for micron-level accuracy, and MES connectivity for full production traceability.
The system captures rich real-time welding data (energy, power, displacement, force) for complete quality monitoring. It includes password protection, parameter logging, QR/barcode scanning for process documentation, and seamless MES integration.
Both models require 380V AC power and 0.55-0.65MPa air connection. Dimensions: 1200*900*1400mm. Weights: TP-WA90 320kg, TP-WA120 340kg. They require dedicated floor space.
Standard machines are ready in 3-5 workdays; customized orders require confirmation. The machine is shipped with a manual and video for self-installation. Technical support is available via phone, email, or video. Spare parts are sent via FedEx or DHL for fast delivery.
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