Based on the visual comparison and cross-sectional analysis of the crimping joints, we conducted tensile and conductivity tests on the wires used in the two crimping processes. The tests were conducted using wires with cross-sectional areas of 0.75mm², 4.0mm², and 16.0mm². The testing methods and standards were in accordance with the requirements of "QC/T 29106-2004 Technical Conditions for Low-Voltage Wire Harnesses for Motor Vehicles."

The ultrasonic wire harness welding machine meets the tensile strength requirements for both crimping and terminal crimping. However, due to the inherent differences in the terminal crimping process, the crimped cross-section often exhibits voids, core wire exposure, and insulation damage, leading to quality defects.

The voltage drop of ultrasonic wire harness welding machines is significantly lower than that of terminal crimping under the same conditions, thereby offering much superior conductive and signal transmission performance compared to terminal crimping. Summarizing, there are three key advantages.

Addressed hollows formed during terminal crimping, enhancing conductivity and overall stability of the electrical system.

2. Reduced heat buildup caused by contact resistance, preventing local temperature increases and quality issues such as wire harness burnout.

Prevented the wire in the harness from being affected by external factors such as moisture, dust, oil, and gas, thereby avoiding copper wire corrosion and oxidation, which could lead to a decrease in conductivity and distortion in signal transmission.