Ultrasonic Wire Splicer


Branson UWS40 ultrasonic splicer meets growing global demand for wire harnesses that deliver splices offering superior electrical and metallurgical performance over crimped, soldered, or resistance-welded connections. The UWS40 delivers these benefits along with added process savings because ultrasonic welding eliminates the need for consumables (no connectors, solder, or filler metals are required), offers extended tool life, and provides significant power savings. It is ideal for rapid, repeatable production of wire harnesses for automobile, agricultural, appliance, recreation, heavy transport equipment, and other industry segments.


The splicer is designed for maximum productivity, whether deployed as a portable unit on a wire harness assembly board or on a tabletop. The splicer bonds copper wires of up to 40 sq. mm in either in-line or pigtail configurations and can be used for wire solidification of stranded copper wires.


The Branson UWS40 consists of three major components-a compact actuator, a controller/power supply, and a 22-in. capacitive touchscreen interface for navigating the user-friendly HMI. The large touchscreen and intuitive HMI enable operators to easily program and select among various welding modes, to develop and save splice, sequence and harness recipes for easy recall, or to develop and configure custom quality-monitoring solutions. Recipes can be recalled using an optional bar-code scanner for quick and easy changes. It calibrates automatically upon startup and remains in standby mode when not in active use. Patented anti-side splice technology supports maximum production by assuring that wires maintain proper vertical stacking and orientation throughout the splicing process.


The actuator and controller monitor and record data for each weld in real time. The controller also conducts statistical analysis to track weld performance trends. To share this data, it offers connectivity to information networks and interfaces with Manufacturing Execution Systems (MES). It can also interface with downstream production equipment, such as shrink-tubing systems.


In addition, the controller monitors all critical splice parameters, such as time, power, pre-height, and final height for each splice, and indicates in real time that the current splice has met all parameters. These indications appear on the HMI or visually through color-coded LED status indicators for quick, easy operator reference. The actuator is also equipped with an in-line cutting module that automatically disables suspect wire combinations to prevent them from entering the downstream manufacturing flow.

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