A wiring harness welding method and a wiring harness welding assembly

Abstract

The application belongs to the technical field of welding, and discloses a wire harness welding method and a wire harness welding assembly. Specifically, a first wire harness, a second wire harness, a terminal and an ultrasonic welding system are provided; a first welding section of the first wire harness is placed on a bottom die; the terminal is placed on the first welding section, and a first welding surface is in abutment with the first welding section; a second welding section of the second wire harness is placed on the terminal, and a second welding surface is in abutment with the second welding section; a welding head is placed on the second welding section, and the ultrasonic welding system is started; and the welding head respectively welds the first welding section and the second welding section to the first welding surface and the second welding surface. The wire harness welding method can realize double-sided welding of the terminal, and can save raw materials and reduce costs. Moreover, through the double-sided welding of the terminal, the contact area of the core wires of the first wire harness and the second wire harness and the terminal is increased, so that the conductivity and the heat conduction performance are improved. The wire harness welding assembly saves raw materials, has low cost, and has good conductivity and heat conduction performance.

Description

Technical Field

[0001] This invention relates to the field of wire harness welding technology, and in particular to a wire harness welding method and a wire harness welding assembly. Background Technology

[0002] With the widespread application of high-power wire harness terminal connectors, ultrasonic welding has also become widely used, especially for welding large-section wire harness terminals. Large-section wire harnesses generally refer to wire harnesses with a total cross-sectional area exceeding 70 square millimeters. Current ultrasonic welding technology typically involves directly welding large-section wire harnesses to metal terminals (hereinafter referred to as terminals). However, this direct welding method consumes a relatively large amount of raw materials, resulting in high costs and large connectors with matching terminals. (The text then discusses welding wires with a diameter of 70mm.) 2 Taking a wire harness and copper plate terminal as an example, if the terminal width is 18mm, the length is 50mm, and the thickness is 3mm, then the volume is 18mm * 3mm * 50mm = 2700mm. 3 Furthermore, the welding area of ​​the wire harness after welding is smaller than the terminal area, so the connector that connects to the terminal needs to be designed to be large in order to connect with the terminal.

[0003] Therefore, there is an urgent need to propose a wire harness welding method and a wire harness welding assembly to solve the above problems. Summary of the Invention

[0004] The first objective of this invention is to provide a wire harness welding method that can save raw materials and costs, improve electrical and thermal conductivity, and provide strong welding position stability.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] A wire harness soldering method includes the following steps:

[0007] S1: Provides a first wire harness, a second wire harness, a terminal, and an ultrasonic welding system, wherein the first wire harness has a first welding section, the second wire harness has a second welding section, the terminal has a first welding surface and a second welding surface, and the ultrasonic welding system includes a bottom mold and a welding head;

[0008] S2: Place the first welding segment on the bottom mold;

[0009] S3: Place the terminal on the side of the first welding section away from the bottom mold, with the first welding surface abutting against the first welding section;

[0010] S4: Place the second welding segment on the side of the terminal away from the bottom mold, with the second welding surface abutting against the second welding segment;

[0011] S5: Place the welding head on the side of the second welding segment away from the bottom mold, start the ultrasonic welding system, and the welding head welds the first welding segment and the second welding segment to the first welding surface and the second welding surface, respectively.

[0012] As an optional technical solution for wire harness welding, step S2 further includes placing the welding head on the side of the first welding segment away from the bottom mold, starting the ultrasonic welding system, and the welding head pre-welding the first welding segment.

[0013] As an optional technical solution for wire harness welding, the wire harness welding method further includes providing a positioning component, the positioning component including two sets of adjusting push blocks, the two sets of adjusting push blocks being able to abut against the two end sides of the first welding segment, the terminal and the second welding segment along the first direction respectively, the distance between the two sets of adjusting push blocks along the first direction being a, the width of the welding head along the first direction being b, and a>b.

[0014] As an optional technical solution for wire harness welding, both the first wire harness and the second wire harness are wire harnesses composed of multiple fine monofilaments, and the distance between the bottom surface of the adjusting push block and the top surface of the bottom mold is less than or equal to the diameter of a single fine monofilament.

[0015] As an optional technical solution for wire harness welding, the inner side of the adjusting push block is provided with a slot, and the two ends of the terminal are respectively inserted into the two slots along the first direction, with the side of the terminal abutting against the bottom wall of the slot.

[0016] As an optional technical solution for wire harness welding, the inner side of the adjusting push block is provided with a clearance space, and the two ends of the terminal along the first direction are respectively locked in the two clearance spaces, so that only the second welding surface and the side of the terminal abut against the inner wall of the clearance space.

[0017] As an optional technical solution for wire harness welding, the welding head welds the first welding segment and the second welding segment, and the terminal moves along a second direction toward the bottom mold, the second direction being perpendicular to the first direction.

[0018] As an alternative technical solution for wire harness welding, the positioning component further includes a pressing structure, which enables the two sets of adjusting push blocks to move along the second direction toward or away from the bottom mold.

[0019] As an optional technical solution for wire harness welding, the wire harness welding method further includes providing a top wire fixture and a clamping wire fixture, wherein the top wire fixture positions the first wire harness and the second wire harness in the axial direction, and the clamping wire fixture positions the first wire harness and the second wire harness in the radial direction.

[0020] The second objective of this invention is to provide a wire harness welding assembly that saves raw materials, has low cost, and good electrical and thermal conductivity.

[0021] To achieve this objective, the present invention adopts the following technical solution:

[0022] A wire harness welding assembly, which is manufactured using the above-described wire harness welding method.

[0023] The beneficial effects of this invention are:

[0024] The wire harness welding method provided by this invention includes a first wire harness, a second wire harness, terminals, and an ultrasonic welding system. A first welding segment of the first wire harness is placed on a base mold; a terminal is placed on the first welding segment, with the first welding surface abutting against the first welding segment; a second welding segment of the second wire harness is placed on the terminal, with the second welding surface abutting against the second welding segment; a welding head is placed on the second welding segment, and the ultrasonic welding system is activated, with the welding head welding the first and second welding segments to the first and second welding surfaces, respectively. By providing two welding wire harnesses (first and second wire harnesses), double-sided welding of the terminals can be achieved, saving materials and costs. Furthermore, double-sided welding of the terminals increases the contact area between the core wires of both the first and second wire harnesses and the terminals, thereby improving electrical and thermal conductivity.

[0025] Providing an ultrasonic welding system enables simultaneous welding of the first and second welding surfaces of terminals, improving welding quality while saving costs. Furthermore, by stacking the first welding segment, terminal, and second welding segment sequentially on the bottom mold, which provides fixed support during welding, and allowing only the welding head to vibrate, the stability of the welding positions of the first welding segment, terminal, and second welding segment is improved during the welding process. Attached Figure Description

[0026] Figure 1 This is a flowchart of the wire harness welding method provided in an embodiment of the present invention;

[0027] Figure 2 This is a schematic diagram of the assembly structure of the positioning component in the wire harness welding method provided in this embodiment of the invention. Figure 1 ;

[0028] Figure 3 yes Figure 2 Enlarged view at point A;

[0029] Figure 4 This is a schematic diagram of the assembly structure of the positioning component in the wire harness welding method provided in this embodiment of the invention. Figure 2 ;

[0030] Figure 5This is a schematic diagram of the assembly structure of the positioning component in the wire harness welding method provided in this embodiment of the invention. Figure 3 ;

[0031] Figure 6 This is a comparison of the materials used in single-sided non-full soldering in the background art with those used in double-sided non-full soldering and double-sided full soldering provided in this embodiment;

[0032] Figure 7 This is an assembly diagram of the top wire tooling and the wire clamping tooling in the wire harness welding method provided in this embodiment of the invention.

[0033] In the picture:

[0034] 100, First wire harness; 110, First welding section; 200, Second wire harness; 210, Second welding section; 300, Terminal; 410, Welding head; 420, Bottom mold; 500, Adjusting push block; 501, Slot; 502, Clearance space; 600, Top wire fixture; 700, Wire clamping fixture. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0036] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0037] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0038] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0039] The wire harness welding method provided in this embodiment can save raw materials and costs, improve electrical and thermal conductivity, and has strong welding position stability.

[0040] Specifically, such as Figure 1 As shown, the wire harness welding method includes the following steps:

[0041] S1: Provides a first wire harness 100, a second wire harness 200, a terminal 300 and an ultrasonic welding system. The first wire harness 100 has a first welding section 110, the second wire harness 200 has a second welding section 210, and the terminal 300 has a first welding surface and a second welding surface. The ultrasonic welding system includes a bottom mold 420 and a welding head 410.

[0042] S2: Place the first welding section 110 on the bottom mold 420;

[0043] S3: Place the terminal 300 on the side of the first welding section 110 away from the bottom mold 420, with the first welding surface abutting against the first welding section 110;

[0044] S4: Place the second welding section 210 on the side of the terminal 300 away from the bottom mold 420, and the second welding surface abuts against the second welding section 210;

[0045] S5: Place the welding head 410 on the side of the second welding section 210 away from the bottom mold 420, start the ultrasonic welding system, and the welding head 410 welds the first welding section 110 and the second welding section 210 to the first welding surface and the second welding surface, respectively.

[0046] In this embodiment, by providing two welding wire harnesses, a first wire harness 100 and a second wire harness 200, to weld the first welding surface and the second welding surface of the terminal 300 respectively, double-sided welding of the terminal 300 can be achieved, saving raw materials and costs. Furthermore, by double-sided welding of the terminal 300, the contact area between the core wires of the first wire harness 100 and the second wire harness 200 and the terminal 300 is increased, thereby improving electrical and thermal conductivity.

[0047] The specific value is based on the requirement of a welding wire diameter of 70mm in the background technology. 2Taking wire harnesses and copper plate terminals as an example, in the background technology, the terminal width is 18mm, the length is 50mm, and the thickness is 3mm, then the volume is 18mm * 3mm * 50mm = 2700mm. 3 In this embodiment, the wire diameter of both the first wire harness 100 and the second wire harness 200 is 35mm. 2 The required terminal 300 has a width of approximately 13mm, a length of 50mm (same as in the prior art), and a thickness of 3mm (same as in the prior art). Therefore, the volume of the terminal 300 is 13mm * 3mm * 50mm = 1950mm². 3 <2700mm 3 .

[0048] It should be noted that the double-sided welding in this embodiment reduces the width of terminal 300. The length (50mm) and thickness (3mm) of terminal 300 in the above example are only values ​​in one embodiment. Of course, in other embodiments, the length and thickness of terminal 300 can be other values.

[0049] Secondly, by providing an ultrasonic welding system, it is possible to simultaneously weld the first and second welding surfaces of the terminal 300, thus saving costs.

[0050] Furthermore, the provided ultrasonic welding system includes a bottom mold 420 and a welding head 410. The first welding segment 110, the terminal 300, and the second welding segment 210 are stacked sequentially on the bottom mold 420. The bottom mold 420 plays a fixed support role in the welding process, and only the welding head 410 vibrates during welding, which improves the stability of the welding position of the first welding segment 110, the terminal 300, and the second welding segment 210 during the welding process.

[0051] It should be noted that the first wire harness 100 and the second wire harness 200 can be made of copper, aluminum, or other metals with excellent conductivity; the terminal 300 can be made of nickel-plated copper, silver-plated copper, aluminum, or other metals with excellent conductivity. The first welding section 110 and the second welding section 210 are the stripped sections at the ends of the first wire harness 100 and the second wire harness 200, respectively, and are used for welding.

[0052] Furthermore, step S2 also includes placing the welding head 410 on the side of the first welding segment 110 away from the bottom mold 420, activating the ultrasonic welding system, and pre-welding the first welding segment 110 with the welding head 410. Pre-welding the first welding segment 110 serves several purposes: firstly, it allows the first welding segment 110 to be pre-welded into a whole, preventing wire slippage during welding in step S5; secondly, it flattens the first welding segment 110 during welding, allowing the terminal 300 to be placed more stably on the first welding segment 110 in step S3; and thirdly, it increases the welding strength of the first wire harness 100, making the tensile strength of the first wire harness 100 and the second wire harness 200 similar after welding with the terminal 300, thus compensating for the low welding strength of the first welding segment 110 caused by the welding head 410 transmitting welding input from the second welding segment 210 to the first welding segment 110.

[0053] like Figures 2 to 5 As shown, in order to increase the positional stability of the first welding segment 110, terminal 300 and second welding segment 210 during the welding process, the wire harness welding method further includes providing a positioning component. The positioning component includes two sets of adjusting push blocks 500, which can respectively abut against the two end sides of the first welding segment 110, terminal 300 and second welding segment 210 along the first direction.

[0054] The first direction is... Figure 2 In direction A.

[0055] Continue as Figure 2 and Figure 3 As shown, in this embodiment, the distance between the two sets of adjusting push blocks 500 along the first direction is a, and the width of the welding head 410 along the first direction is b, where a>b, to leave vibration space for the welding head 410 and avoid friction between the welding head 410 and the adjusting push block 500.

[0056] Both the first wire harness 100 and the second wire harness 200 are wire harnesses composed of multiple fine monofilaments, and the cross-sectional area of ​​the wire harness is circular. In this embodiment, the diameter of a single fine monofilament is greater than 0.05 mm.

[0057] Therefore, the vibration space should not be too large, otherwise it will cause the wire harness to slack. So usually the vibration space on one side is less than or equal to 0.05mm, that is, ab≤0.1mm.

[0058] Similarly, the distance between the bottom surface of the pusher block 500 and the top surface of the bottom mold 420 is less than or equal to the diameter of the fine monofilament to prevent wire fraying. In this embodiment, the distance between the bottom surface of the pusher block 500 and the top surface of the bottom mold 420 can be exemplarily 0.01mm, 0.02mm, 0.03mm, 0.04mm, 0.05mm, etc.

[0059] In this embodiment, the width of the bottom mold 420 along the first direction is equal to the width of the welding head 410 along the first direction.

[0060] In other embodiments, the width of the bottom mold 420 along the first direction is not equal to the width of the welding head 410 along the first direction.

[0061] In one specific embodiment, this wire harness welding method enables full welding of both the first and second welding surfaces of the terminal 300. Continuing as... Figure 2 As shown, in order to achieve full welding on both the first and second welding surfaces of the terminal 300, the first welding segment 110, the terminal 300 and the second welding segment 210 are flush with the end sides along the second direction along the first direction.

[0062] In another specific embodiment, this wire harness welding method enables double-sided non-full soldering of the first and second soldering surfaces of the terminal 300. Continuing as... Figure 4 As shown, in order to achieve double-sided non-full welding of the first and second welding surfaces of the terminal 300, the inner side of the adjusting push block 500 is provided with a slot 501. The two ends of the terminal 300 are respectively inserted into the two slots 501 along the first direction, and the side of the terminal 300 abuts against the bottom wall of the slot 501.

[0063] It should be noted that the second welding surface abuts against the side wall of the slot 501, and there is a gap between the first welding surface and the side wall of the slot 501, which is smaller than the diameter of a single thin filament. It can be seen that the groove depth of the slot 501 is half the difference between the width of the terminal 300 along the first direction and the distance 'a' between the two sets of adjusting push blocks 500.

[0064] In yet another specific embodiment, this wire harness welding method enables full soldering of the first welding surface and partial soldering of the second welding surface of the terminal 300. Continuing as... Figure 5 As shown, in order to achieve full welding on the first welding surface of the terminal 300 and non-full welding on the second welding surface, i.e., one side is fully welded and the other side is not fully welded, the inner side of the adjusting push block 500 is provided with a clearance space 502. The two ends of the terminal 300 along the first direction are respectively locked in the two clearance spaces 502, so that only the second welding surface and the side of the terminal 300 abut against the inner wall of the clearance space 502.

[0065] Similarly, the depth of the clearance space 502 along the first direction is half the difference between the width of the terminal 300 along the first direction and the distance a between the two sets of adjusting push blocks 500.

[0066] As the welding head 410 welds the first welding segment 110 and the second welding segment 210, and as the first welding segment 110 and the second welding segment 210 are compressed, in this embodiment, the terminal 300 moves along the second direction toward the bottom mold 420, and the second direction is perpendicular to the first direction.

[0067] The second direction is... Figure 2 In this embodiment, the second direction (direction B) is the vertical direction.

[0068] Furthermore, the adjusting push block 500 also needs to move in the second direction toward the bottom mold 420 in order to cooperate with the movement of the terminal 300 in the second direction. In this embodiment, the positioning component also includes a pressing structure (not shown in the figure), which enables the two sets of adjusting push blocks 500 to move in the second direction toward or away from the bottom mold 420.

[0069] The following is a comparison of the raw material volumes used in single-sided partial welding (the welding method in the background art), double-sided partial welding, and double-sided full welding, as follows: Figure 6 As shown:

[0070] Welding methods: Method 1, single-sided non-full welding; Method 2, double-sided non-full welding; Method 3, double-sided full welding.

[0071] Symbol definitions: Terminal 300 length L, Terminal 300 welding end thickness T, Terminal 300 outer diameter D (corresponding to the three welding methods D1, D2, D3 respectively), Terminal 300 welding end width W. b (The three welding methods correspond to W) b1 W b2 W b3 ), Welding width W a (The three welding methods correspond to W) a1 W a2 W a3 Unwelded width W c (The three welding methods correspond to W) c1 W c2 W c3 (not shown in the figure).

[0072] Terminal 300 is usually machined from a round bar with an outer diameter slightly larger than D. For now, we will not consider the machining loss, so the minimum raw material size of the terminal is a round bar with a diameter of D and a length of L.

[0073] Among them, the minimum value of the terminal outer diameter D is D min The corresponding cross-sectional circle is W. b The minimum envelope surface of T, i.e., D min 2 =W b 2 +T 2 ,

[0074] Then the minimum value of the cross-sectional area S of the raw material is S min =Pi x D min 2 / 4=Pi x(W b 2 +T 2 ) / 4.

[0075] The minimum value of the required raw material volume V is V min =Pi x(W b 2 +T 2 )x L / 4. (Corresponding to three welding methods: V1, V2, and V3).

[0076] For method one, since it is not a full weld, W can be obtained. b1 =W a1 +W c1 That is, W b1 >W a1 .

[0077] For method two, since it is not a full weld, we can obtain W. b2 =W a2 +W c2 That is, W b2 >W a2 .

[0078] For method three, due to full soldering, W can be obtained. b3 =W a3 .

[0079] Among them, since the welding width of double-sided welding is smaller than that of single-sided welding, i.e. W a1 >W a2 =W a3 .

[0080] Among them, because we want to let W... c1 =W c2 We can obtain W b1 >W b2 .

[0081] Then we can obtain W b1 >W b2 >W b3 =W a2 =W a3 .

[0082] Therefore, V1>V2>V3.

[0083] Furthermore, the raw material volume saved by method two compared to method one is ΔV 12 =V1-V2=Pi x(W) b1 2 -W b2 2 )x L / 4,

[0084] The amount of raw material saved by method three compared to method two is ΔV.23 =V2-V3=Pi x(W) b2 2 -W b3 2 )x L / 4.

[0085] It is evident that double-sided full welding in this wire harness welding method saves the most materials, followed by double-sided partial welding. Both double-sided partial welding and single-sided partial welding in the prior art save more materials.

[0086] like Figure 7 As shown, in order to better fix and position the first wire harness 100 and the second wire harness 200, the wire harness welding method further includes providing a top wire fixture 600 and a wire clamping fixture 700. The top wire fixture 600 positions the first wire harness 100 and the second wire harness 200 in the axial direction, and the wire clamping fixture 700 positions the first wire harness 100 and the second wire harness 200 in the radial direction.

[0087] In this embodiment, the specific process of the wire harness welding method is as follows:

[0088] Provided are a first wire harness 100, a second wire harness 200, a terminal 300, an ultrasonic welding system, a positioning assembly, a top wire fixture 600, and a wire clamping fixture 700. The ends of the first wire harness 100 and the second wire harness 200 are stripped to form a first welding section 110 and a second welding section 210, respectively; the first welding surface and the second welding surface of the terminal 300 are determined.

[0089] Adjust the distance a between the two sets of adjusting push blocks 500 after they extend along the first direction, so that the distance a after they extend is larger than the width b of the welding head 410, but the value of 1 / 2 (ab) should not be greater than the diameter of the single fine wire, and the distance between each set of adjusting push blocks 500 and the welding head 410 should not be greater than the diameter of the single fine wire; adjust the position of the bottom mold 420 and the adjusting push blocks 500 so that the distance between the bottom mold 420 and the adjusting push blocks 500 along the second direction is less than or equal to the diameter of the single fine wire.

[0090] It should be noted that the two sets of adjusting push blocks 500 can move closer and further apart along the first direction to adjust the distance a between the two sets of adjusting push blocks 500 when they are working.

[0091] First, push the first wire harness 100 to the top wire fixture 600 so that the first welding section 110 of the first wire harness 100 is placed on the bottom mold 420, and then use the wire clamping fixture 700 to fix the first wire harness 100.

[0092] Next, the terminal 300 is placed on the side of the first welding section 110 away from the bottom mold 420, and the first welding surface abuts against the first welding section 110.

[0093] At this time, the two sets of adjusting push blocks 500 are extended and clamped at both ends of the first welding section 110 and the terminal 300 along the first direction.

[0094] Next, after the second wire harness 200 is pushed onto the top wire fixture 600, the second welding section 210 of the second wire harness 200 is placed on the side of the terminal 300 away from the bottom mold 420, and the second welding surface abuts against the second welding section 210. Then, the second wire harness 200 is fixed with the wire clamping fixture 700.

[0095] Finally, place the welding head 410 on the side of the second welding section 210 away from the bottom mold 420 and between the two sets of adjusting push blocks 500, start the ultrasonic welding system, and press down the welding head 410 to weld the second welding section 210.

[0096] During the welding process, the pressing structure pushes the two sets of adjusting push blocks 500 to move along the second direction toward the bottom mold 420.

[0097] The wire harness welding assembly provided in this embodiment saves raw materials, has low cost, and has good electrical and thermal conductivity.

[0098] This wire harness welding assembly is manufactured using the aforementioned wire harness welding method. It includes two welding wire harnesses, a first wire harness 100 and a second wire harness 200. The first wire harness 100 and the second wire harness 200 are welded to the terminal 300 on both sides. Compared with single-sided welding, the width of the terminal 300 needs to be smaller, thus saving on terminal manufacturing materials and reducing costs. Furthermore, double-sided welding allows the first wire harness 100 and the second wire harness 200 to contact the terminal 300 on both sides, increasing the contact area between the core wires of the two wire harnesses and the terminal, thereby improving the electrical and thermal conductivity of the entire wire harness welding assembly.

[0099] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A harness welding method characterized by, The method comprises the following steps: S1: providing a first wire harness (100), a second wire harness (200), a terminal (300) and an ultrasonic welding system, the first wire harness (100) having a first welding section (110), the second wire harness (200) having a second welding section (210), the terminal (300) having a first welding surface and a second welding surface, and the ultrasonic welding system comprising a bottom die (420) and a welding head (410); S2: placing the first welding section (110) on the bottom die (420); S3: placing the terminal (300) on the side of the first welding section (110) away from the bottom die (420), with the first welding surface abutting the first welding section (110); S4: placing the second welding section (210) on the side of the terminal (300) away from the bottom die (420), with the second welding surface abutting the second welding section (210); S5: placing the welding head (410) on the side of the second welding section (210) away from the bottom die (420), starting the ultrasonic welding system, and welding the first welding section (110) and the second welding section (210) to the first welding surface and the second welding surface, respectively, by the welding head (410); The wire harness welding method further comprises providing a positioning assembly, the positioning assembly comprising two sets of adjusting push blocks (500), the two sets of adjusting push blocks (500) being capable of abutting the two end sides of the first welding section (110), the terminal (300) and the second welding section (210) in a first direction, respectively, the distance between the two sets of adjusting push blocks (500) in the first direction being a, and the width of the welding head (410) in the first direction being b, with a > b.

2. The wire harness welding method according to claim 1, characterized by, The step S2 further comprises placing the welding head (410) on the side of the first welding section (110) away from the bottom die (420), starting the ultrasonic welding system, and pre-welding the first welding section (110) by the welding head (410).

3. The wire harness welding method according to claim 1, characterized by, The first wire harness (100) and the second wire harness (200) are both wire harnesses composed of a plurality of fine filaments, and the distance between the bottom surface of the adjusting push block (500) and the top surface of the bottom die (420) is less than or equal to the diameter of a single fine filament.

4. The wire harness welding method according to claim 1, characterized by, The inner side of the adjusting push block (500) is provided with a slot (501), and the terminal (300) is inserted into the two slots (501) at the two ends in the first direction, respectively, with the side surface of the terminal (300) abutting the bottom wall of the slot (501).

5. The wire harness welding method according to claim 1, characterized by, The inner side of the adjusting push block (500) is provided with an avoiding space (502), and the terminal (300) is clamped into the two avoiding spaces (502) at the two ends in the first direction, respectively, with only the second welding surface and the side surface of the terminal (300) abutting the inner wall of the avoiding space (502).

6. The wire harness welding method according to any one of claims 4 or 5, characterized by, The welding head (410) welds the first welding segment (110) and the second welding segment (210), and the terminal (300) moves along a second direction toward the bottom mold (420), the second direction being perpendicular to the first direction.

7. The wire harness welding method according to claim 6, characterized by, The positioning component also includes a pressing structure that enables the two sets of adjusting push blocks (500) to move along the second direction toward or away from the bottom mold (420).

8. The wire harness welding method according to claim 1, characterized by, The wire harness welding method further includes providing a top wire fixture (600) and a clamping wire fixture (700), wherein the top wire fixture (600) positions the first wire harness (100) and the second wire harness (200) in the axial direction, and the clamping wire fixture (700) positions the first wire harness (100) and the second wire harness (200) in the radial direction.

9. A wiring harness weld assembly characterized by, The wire harness welding assembly is manufactured using the wire harness welding method according to any one of claims 1-8.

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