Automotive Relay to IP67 Fuse Box Cable Aassembly
Product Description
This custom wire assemblies applied for automotive pressure switch system to FAN, RELAY parts. which processed with special copper ultrasonic welding for wire joint connection, which replaced common splice PNT terminal.
We have developed a tradition of high-tech engineering, prototyping, and quality Custom Cable manufacturing at very competitive pricing for wire assembling. Also with professional flow chart (wire cutting-stripping-copper twisting-crimping-crimping 100% inspection-soldering-molding-asssembling-braiding-testing-FQC100% -OQC) , which can help us support customers with stable quality.
Product Specifications
| Product Name | Automotive Relay to IP67 Fuse Box Cable Aassembl | ||
| Application | automotive pressure switch system | ||
| Cable color | Per customer requirements | ||
| Cable Length | Per customer requirements | ||
| Outer Insulation Material | XLPE(Irradiated wire) | ||
| Cable Jacket | XLPE automtive wire GXL, TXL | ||
| Connectors type | originanl or local equivalent auto relay connector, auto waterproof fuse connector, auto molded plug as customer request | ||
| Pin out connection | As per customer’s request | ||
| Inner Copper | Tin-plated / Bare Copper | ||
| Cable protection | Covered with split corrugated tube 94V-0 & 3M taping | ||
| Joint connection | Ultrasonic welding replaced common splice terminal | ||
| Quality Certificate | ISO9001, IATF16949, ROHS, UL,SGS,REACH | ||
| Performance Test: | 100% terminal inspection & 100% electric testing & 100% FQC & AQL=0.65 | ||
Product Details
01 Ultrasonic welding is a welding process in which ultrasonic waves or vibrations are used to generate heat for welding. Ultrasonic means those vibration waves which have frequency above the normal hearing range. It is about 20000 to 30000 Hz.
Ultrasonic welding can be used to bond the metal in less time and at lower temperatures than traditional welding. Ultrasonic welding does have its limitations, though. First, the depths of the welds are less than a millimeter, so the process works best on thin materials like plastics, wires or thin sheets of metal.
Ultrasonic welding has many advantages over traditional methods. For one, welding occurs at low temperatures relative to other methods. So, the manufacturer does not need to expend vast amounts of fuel or other energy to reach high temperatures. This makes the process cheaper. It's also faster and safer.The process occurs in fractions of a second to seconds.
Finally, ultrasonic welds are as strong and durable as conventional welds of the same materials -- which is just one of the reasons the method is being used in car manufacturing. To make cars lighter and more fuel efficient, auto makers are turning to aluminum as the main metal in car bodies. Ultrasonic welding can be used to bond the metal in less time and at lower temperatures than traditional welding.
02 The IP67 waterproofing fuse box with local equivalent one, and the end butt terminal also crimped following IPC620 standard. And the joint connected terminal all crimped following IPC620-C standard, to use ultrasonic welding method to repalce common splice terminal. The welded appearance as below, together with the required welding spec and Ultrasonic quality controlling:
Poor quality:
a)Insulation is embedded in weld nugget
b)End of insulation is lesss than 1 wire diameter or more than 2 wire diameters from weld nugget.
c)Insulation gap is so large that it causes the conductor toviolate minimum electrical spacing.
d)Any loose wire strands, any discoloration of the conductors;
e)Nugget width to height ratio is less than 1 to 1 or exceeds 2 to 1.
ETOP controlled quality:
a) End of insulation is between 1 and 2 wire diameters from weld bugget;
b) Nugget width to heigt ratio is 1.5 to 1; or at least 1 to 1 but does not exceed 2 to 1;
c) Individual wire strands are distinguishable on compression surfaces（top & bottom) of nugget. And there are no loose strands.
03 The IP67 waterproofing fuse box with local equivalent one, which can be customized to be original AVL one. Fuse is 5A, also the connector designed with waterproofing silicone seal and cap.
04 The 5pin automitve relay connector with locking hook to fix during assembling. The Automotive relays are for use in 12 volt electrical systems.Relays are used when you need to switch higher currents than a switch can handle, or when you want to isolate an electrical circuit.
Product Video
Here is the vedio for ultrasonic welding fixture testing and process.
Product Applications
The pressure switch is an important component on many of our electric models. This customized auto wire assembly are applied for automotive air conditioner's pressure switch system, which cycles the vehicle's compressor on and off when the refrigerant pressure falls below an acceptable level. This protects the compressor from damage.
The ETOP custom automobile wiring harnesses are also used for audio, ECU, Hybird battery, engine, GPS, mirror, rear-view, ADAS, auto seat, Buzz and sensor, Lamp, dieseal valve cover gasket fit, fuel pump, diagnostic OBD system., etc.