Hot crimping resistance welding system joins insulated copper wire to cable shoes

Amada Miyachi Europe has announced the availability of a hot crimping resistance welding system suitable for joining insulated copper wire to cable shoes or terminals.

The system includes weld heads, transformer, power supply, and process monitor. It provides a fast, cost-effective alternative to removing copper wire coating by lasers or mechanical means before making the electrical connection, the company states.

A weld to displacement feature allows the equipment to be programmed to reach the specified compression, after which the current flow and heating is switched off. This compensates for part-to-part variation and lets users program a parameter that is closely related to joint quality.

Systems range from the highly delicate, fine control required to hot-crimp wires as small as 40 µm to the high power and high force required for very large wires.

A high-force Miyachi Peco weld head mechanically holds the electrodes and feeds the electrical current to them. An integrated water cooling system actively cools all components to prevent overheating during production. The resistance welding system also features a Miyachi Peco power supply and transformer and a Miyachi Peco MG3 process monitor.