Modeling of the Impact of Ultrasonic Welding of Harness on the Terminals Integrity 2014-01-0224
The ultrasonic (US) welding of wires in automotive harnesses is increasingly used as an alternative to mechanical splices. However, this welding process may harm the electrical terminals crimped on the wires ends as a result on the energy propagation along the wire up the terminal with a frequency that is close to the terminals' natural frequencies. The modeling of the ultrasonic welding had been investigated by several authors from the process and weld strength perspective but the modeling of its effect on electrical terminals in automotive harnesses has not been given much attention in the literature.
This paper describes and illustrates approaches used for modeling of the impact of the US welding on the electrical terminals in terms of stress and deformation from qualitative and quantitative perspectives and the related benefits/limitations from predictive standpoint. Illustrations are given on an actual terminal with respect to a typical ultrasonic welding process.