In Nanjing Jiangning Economic and Technological Development Zone, a company that supplies charging gun components to new car manufacturers is facing severe challenges: the connection process between glass fiber reinforced nylon (PA6-GF30) and copper terminals has a 23% false soldering rate, resulting in a quarterly loss of more than 1.5 million yuan. This real case reflects the common problems faced by the Nanjing auto parts industry: welding stability of lightweight materials, reliability of electrical connections, and assembly accuracy of multi-material composite structures.
Technical pain points lead to process innovation
The rapid development of Nanjing's new energy vehicle industry chain has driven welding technology to move towards precision iteration. When welding carbon fiber reinforced plastics (CFRP), traditional hot plate welding causes 38% of welds to delaminate due to uneven thermal conductivity of the material; when resistance welding aluminum alloy parts, the excessive heat-affected zone causes a 15% decrease in fatigue strength. These pain points are driving local companies to seek more advanced connection solutions.
Technological breakthroughs for innovative welding scenarios
Electric drive system packaging: A motor controller manufacturer in Jiangbei New District uses 20kHz ultrasonic welding equipment to achieve copper-aluminum composite busbar welding of IGBT modules. The welding strength reaches 220N/cm², which is 3 times more efficient than traditional laser welding and completely eliminates the risk of metal spatter.
Intelligent sensor assembly: In the Nanjing Autonomous Driving Demonstration Zone, the PC/ABS welding of the millimeter-wave radar bracket uses digital amplitude control technology to stabilize the dimensional tolerance at 0.05mm, meeting the millimeter-level assembly requirements of the ADAS system.
Lightweight structural parts connection: A battery tray manufacturer used a multi-stage welding process to successfully connect 2.5mm thick CFRP and aluminum alloy frame, with a shear strength of 45MPa, saving 70% curing time compared to the adhesive bonding process.
Engineering verification of technological advantages
In the Nanjing automotive industry cluster, the unique value of ultrasonic welding is reflected in three dimensions:
Non-thermal welding: Molecular friction heat is generated by high-frequency vibration of 40,000 times per second. When welding polyamide materials, the substrate temperature only rises by 8°C, perfectly protecting the built-in electronic components.
Dynamic process control: The intelligent system monitors the change of welding impedance in real time and controls the energy fluctuation within 3% during the welding of 0.5mm² wires at a wiring harness company in Nanjing
Multi-material adaptability: The latest broadband tracking technology can automatically match the welding parameters from TPU soft glue to PPS engineering plastics, achieving 100% airtight qualification rate in the production of wiper seals
The value of localized technical solutions
As a professional equipment manufacturer deeply involved in automobile manufacturing, the technological evolution of apsonic ultrasonic is highly consistent with industry needs. The "double closed-loop control system" it developed has been verified in a new energy vehicle company in Jiangning: when welding the charging gun shell containing 35% glass fiber, the welding strength dispersion coefficient was reduced from 18% to 3.5% by real-time compensation of amplitude deviation.
Aiming at the special needs of new energy vehicles, the automotive-specific database built by apsonic has included welding parameters for 120 types of automotive materials. Application data of a certain electric control box production line shows that when switching between different batches of PC/ABS materials, the equipment automatically adjusts the welding time deviation by 0.02 seconds, helping customers pass the IATF 16949 process audit.
In the field of intelligent driving sensors, apsonic's micro-welding modules (welding area 1.2mm²) have been successfully used in the production of millimeter-wave radar brackets. After welding, the components have passed 2000 temperature cycle tests from -40°C to 125°C, and the dimensional stability has reached the SAE J1455 standard.
Nanjing's automobile industry is undergoing a deep transformation from "manufacturing" to "intelligent manufacturing". As a key process link, the breakthrough of welding technology is directly related to the competitiveness of the industrial chain. Through continuous technology iteration and industry know-how accumulation, apsonic provides local companies with innovative and reliable solutions. In Nanjing's advantageous fields such as lightweight material application, electric drive system integration, and intelligent component assembly, this precise connection between technology supply and industry demand is reshaping the manufacturing standards of automotive parts. According to statistics from the Nanjing Intelligent Equipment Association, Tier 1 suppliers using professional welding equipment have shortened their new product development cycle by an average of 22%, which may indicate that technological innovation is being transformed into real industrial competitiveness.
