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BS EN IEC 60352-9:2024 Solderless connections - Ultrasonically welded connections. General requirements, test methods and practical guidance, 2024
- undefined [Go to Page]
- Annex ZA (normative)Normative references to international publicationswith their corresponding European publications
- English [Go to Page]
- CONTENTS
- FOREWORD
- INTRODUCTION
- 1 Scope
- 2 Normative references
- 3 Terms and definitions
- Figures [Go to Page]
- Figure 1 – Ultrasonic welding machine designed to make splicesbetween at least two wires
- Figure 2 – Ultrasonically welded splice of two wires protected by a shrinking tube
- Figure 3 – Top view of an ultrasonically welded wire on a terminal
- Figure 4 – Side view of an ultrasonically welded wire on a terminal
- Figure 5 – Ultrasonically welded end compaction
- 4 Wire and terminal information [Go to Page]
- 4.1 Conductor materials
- 4.2 Conductor surface coating
- 5 Requirements for ultrasonic welding [Go to Page]
- 5.1 Examples of ultrasonically welded connections
- Figure 6 – Ultrasonically welded end splice connection
- Figure 7 – Welding zone (1) for two stripped wires withheat shrink tubing (2) for insulation
- Figure 8 – Ultrasonically welded end compaction
- Figure 9 – Ultrasonically welded end splice
- Figure 10 – Ultrasonically welded inline splice Cu-Al
- Figure 11 – Ultrasonically welded inline splice Cu-Cu
- Figure 12 – Example 1 of ultrasonic welding on terminals
- Figure 13 – Example 2 of ultrasonic welding on terminals
- Figure 14 – Example 3 of ultrasonic welding on terminals
- Figure 15 – Example 4 of ultrasonic welding on terminals
- Figure 16 – Example of multiple wires welded to one terminals
- 5.2 General requirements
- 5.3 Influence of wire length for welds at the other end of terminal connections
- 5.4 Design requirements
- Figure 17 – Illustration of the conductor length (3)between terminal (2) and welded package (1)
- Figure 18 – Cross-sectional view of ultrasonic propagation through the sonotrode in the welding room, against passive surfaces with and without gap between the tools
- Figure 19 – Cross-sectional view of recommended asymmetrical insertion for the individual conductors above the sonotrode in the welding room
- Figure 20 – Cross-sectional alternative view of the recommended asymmetrical insertion for the individual conductors above the sonotrode
- 5.5 Mechanical and electrical protection of the weld package
- Figure 21 – Insulation measures at the inline splicefrom one conductor to several conductors
- Figure 22 – Insulation measures at the feed-inline splicewith several conductors on both sides
- Tables [Go to Page]
- Table 1 – Ultrasonically welded packages suggested values
- 5.6 Conductor combinations – requirements
- 5.7 Compaction ratio of ultrasonically welded connections
- Figure 23 – Insulation measures at the end splice with several conductors (end sealed)
- Table 2 – Conductor combinations
- Figure 24 – Cu-wire compaction ratio from strong to weak layout
- Figure 25 – Conductor before and after welding
- 6 Specimens [Go to Page]
- 6.1 General
- 6.2 Type A1 or A2 specimen
- 6.3 Type B1 or B2 specimen
- Figure 26 – Type A1 specimen
- Figure 27 – Type A2 specimen
- 6.4 Type C specimen
- Figure 28 – Type B1 specimen, inline splice with two wires type 1 and type 2
- Figure 29 – Type B2 specimen
- Figure 30 – Type C specimen, end-splice connection with type 3 and type 4 wires
- 6.5 Type D specimen
- 7 Tests [Go to Page]
- 7.1 General information about tests [Go to Page]
- 7.1.1 General conditions for product qualification tests
- 7.1.2 Pre-conditioning
- 7.1.3 Recovery
- 7.2 Visual optical inspection (VOI) with dimensional checks [Go to Page]
- 7.2.1 General
- Figure 31 – Type D specimen at the wire to terminal connection [Go to Page]
- 7.2.2 Magnification aids (visual optical inspection, VOI)
- 7.2.3 Visual inspection of the ultrasonic splice welding
- Table 3 – Magnification suggestions for visual inspection
- Table 4 – Example of good welds for end splices and inline splices [Go to Page]
- 7.2.4 Visual inspection of ultrasonically welded wire to terminal
- Table 5 – Representation of error characteristics for end splices and inline splices
- Figure 32 – Measurement of the ultrasonic weld height
- Figure 33 – Measurement of the ultrasonic weld width (2)
- Table 6 – Valid features of ultrasonically welded wire on terminal
- 7.3 Mechanical tests [Go to Page]
- 7.3.1 Bending test inline splice
- Table 7 – Non-valid features of ultrasonically welded wire on terminal [Go to Page]
- 7.3.2 Bending test on ultrasonically welded wire to terminal
- 7.3.3 Peel test of the splice
- Figure 34 – Bending test setup schematic illustration
- Figure 35 – Terminal bending test setup schematic illustration
- Figure 36 – Test setup for peel tests
- Table 8 – Peel force values for ultrasonically welded splices of copper wires
- Table 9 – Peel force values for ultrasonically welded splices of aluminium wires [Go to Page]
- 7.3.4 Peel tests of the terminal-welded package
- Figure 37 – Test setup for the peel test, fixation (4), side fixations with a protrusion of 1,0 mm each on the terminal surface, ultrasonically welded package (1), terminal (3)
- Table 10 – Peel force values for ultrasonically welded copper wires on terminals [Go to Page]
- 7.3.5 Pull-out force tests on ultrasonic splice-welded connections
- Figure 38 – Test setup for pull-out force test
- Table 11 – Peel force values for ultrasonically welded aluminium wires on terminals
- Table 12 – Pull-out force values for ultrasonically welded splices of copper wires [Go to Page]
- 7.3.6 Pull-out force tests of ultrasonically welded wire-to-terminal connections
- Table 13 – Pull-out force values for ultrasonically welded splices of aluminium wires
- Figure 39 – Test setup for the pull-out force test on welds with electrical conductors on terminal
- Table 14 – Pull-out force values for ultrasonically welded copper wires on terminals
- Table 15 – Dependence of package width on conductor cross-sectional areafor copper wires (recommended)
- Table 16 – Pull-out force values for ultrasonically welded aluminium wires on terminals [Go to Page]
- 7.3.7 Vibration test of ultrasonically welded splice connections
- Figure 40 – Test setup for vibration test of the splice
- Table 17 – Dependence of package width on conductor cross-sectional areafor aluminium wires (recommended) [Go to Page]
- 7.3.8 Vibration test of ultrasonically welded wire-to-terminal connections
- Figure 41 – Setup for vibration test of the ultrasonically welded package (1), vibration table (5), fixtures (2), terminal (4), reference wire with counter-contact connector (7)
- Table 18 – Vibration test (sinusoidal) parameters of ultrasonically welded splice connections [Go to Page]
- 7.3.9 Compaction force test of end splices
- Figure 42 – Aluminium single wire end splice (wire end compacted)
- Figure 44 – Medium copper single wire end splice (wire end compacted)
- Figure 45 – Large copper single wire end splice (wire end compacted)
- Figure 46 – Examples of test clamps of different sizes
- 7.4 Microsection image inspections
- Figure 47 – Example 1 of a valid microsection imageof ultrasonically welded copper strands
- Table 19 – Requirements for single end compaction test
- 7.5 Electrical tests [Go to Page]
- 7.5.1 Voltage drop of the through or end splice (resistance)
- Figure 48 – Example 2 of a valid microsection imageof ultrasonically welded copper strands
- Figure 49 – Example 3 of a valid microsection imageof ultrasonically welded copper strands
- Figure 50 – Set-up for measurement at the splice (from 2 to 20 wires)
- Figure 51 – Measurements of reference wires type 1 and type 2 [Go to Page]
- 7.5.2 Voltage drop of the wire-to-terminal connection (resistance)
- Figure 52 – Setup for voltage drop measurement (U1), at the terminal weld connections [Go to Page]
- 7.5.3 Current-carrying capacity
- Figure 53 – Voltage drop measurement (U2) with the same reference wire (1)
- Figure 54 – Setup for temperature rise measurements at current load [Go to Page]
- 7.5.4 Insulation resistance
- 7.5.5 Voltage proof
- Figure 55 – Temperature chamber with valve opening for current-load measurements
- 8 Climatic tests [Go to Page]
- 8.1 General information on climatic tests
- 8.2 Rapid change of temperature
- Figure 56 – Diagram of dielectric voltage withstanding (voltage proof) test
- Table 20 – Test voltages for voltage proof test
- 8.3 Dry heat
- 8.4 Cold
- 8.5 Damp heat
- 8.6 Climatic sequence
- 8.7 Flowing mixed gas corrosion
- 9 Classification into product classes [Go to Page]
- 9.1 General
- 9.2 Class A product
- 9.3 Class B product
- 9.4 Class C product
- 10 Test schedules [Go to Page]
- 10.1 Test schedule A (class A products, see 9.2)
- Table 21 – Test group P0 – Initial inspection
- 10.2 Test schedule B (class B product, see 9.3) [Go to Page]
- 10.2.1 General
- 10.2.2 Mechanical tests of test schedule B
- Table 22 – Test group P1 – Bending test [Go to Page]
- 10.2.3 Electrical tests of test schedule B
- Table 23 – Test group P2 – Peel test according to ISO 10447
- Table 24 – Test group P3 – Pull-out force test
- Table 25 – Test group P4 – Compaction-force for single wire end-splices
- Table 26 – Test group P6 – Voltage drop (resistance)
- Table 27 – Test group P7 – Insulation resistance [Go to Page]
- 10.2.4 Microsection tests of test schedule B
- 10.3 Test schedule C (class C products, see 9.4) [Go to Page]
- 10.3.1 General
- Table 28 – Test group P10 – Microsection
- Table 29 – Test group P0 – Initial inspection [Go to Page]
- 10.3.2 Mechanical tests according to test schedule C
- 10.3.3 Electrical tests according to test schedule C
- Table 30 – Test group P2 – Peel tests
- Table 31 – Test group P3 – Pull-out force tests
- Table 32 – Test group P4 – Compaction-force test for single wire end-splices
- Table 33 – Test group P5 – Vibration test (sinusoidal)
- Table 34 – Test group P6 – Voltage drop (resistance) [Go to Page]
- 10.3.4 Microsection of test schedule C
- 10.3.5 Climatic test for test schedule C
- Table 35 – Test group P7 – Insulation resistance
- Table 36 – Test group P8 – Current-carrying capacity
- Table 37 – Test group P10 – Microsection
- Table 38 – Test group P11 – Climatic tests
- 11 Additional applicable test groups (if required) [Go to Page]
- 11.1 Dry heat test and voltage proof
- 11.2 Corrosion
- Table 39 – Test group P9 – Voltage proof
- Table 40 – Test group P12 – Corrosion
- Figure 57 – Test schedule A
- Figure 58 – Test Schedule B
- Figure 59 – Test schedule C part 1
- Figure 60 – Test schedule C part 2
- Annex A (informative)Practical guidance [Go to Page]
- A.1 Ultrasonic welding system
- A.2 Storage conditions and processing conditions
- Figure A.1 – Ultrasonic welding process: 1) longitudinal, 2) torsional
- A.3 Processing technique [Go to Page]
- A.3.1 General tooling technology requirements
- A.3.2 Monitoring
- Bibliography [Go to Page]