What are the splice methods wire harness manufacturing, what's their advantage and disadvantage?
There are 3 methods of splice in wire harness manufacturing, like below.
1, Soldered Splices
Advantages:
High mechanical strength, stronger tensile and vibration resistance
Good signal stability: Welding can reduce contact resistance and signal loss, especially suitable for high-frequency and high-power RF transmission scenarios
Long term reliability: Solder joints are not prone to performance degradation due to environmental changes such as temperature fluctuations and oxidation.
Disadvantages:
High process complexity: requires professional welding tools and operational skills, improper operation can easily lead to virtual welding or thermal damage
Difficulty in maintenance: Once welding is completed, dismantling or replacing requires reheating the welding points, which may affect other components
2, Crimped Splices
Advantages:
No need for solder: the copper wire of the wire is uniformly physically pressed together through the terminal to form a cold solder, and the pure metal surface of the conductor and the terminal sleeve are in full and close contact
Easy to operate, high efficiency: fast crimping process, suitable for large-scale production
No thermal stress: there will be no stress in the solder due to temperature changes
Disadvantages:
Additional materials are required, such as snap rings, which will increase material costs
High process requirements: The quality of crimping directly affects the mechanical and electrical performance of the connection
3, Ultrasonic Welded Splices
Advantages:
Fast energy-saving: Utilizing the vibration energy of ultrasonic frequency to frictionally fuse metal surfaces without the need for additional materials such as terminals, solder or flux
High fusion strength and good conductivity: direct metal welding, high connection strength, excellent conductivity
Environmental protection and safety: close to cold processing, no sparks, is the development trend of wire harness contacts
Disadvantages:
High equipment cost: welding equipment prices and maintenance costs are relatively high
