In the automated production of automotive electrical components and electronic controllers, resistance welding has become one of the core welding processes, thanks to its advantages of high efficiency, stable welding quality, and easy integration with automated production lines. Its application scenarios cover the manufacturing of key components such as Electronic Control Units (ECUs), sensors, motor controllers, and on-board power supplies, with the function of achieving precise welding of conductive materials like copper, aluminum, and copper alloys.
I. Core Application Scenarios of Resistance Welding in Automotive Electrical Components and Electronic Controllers
The core of automotive electrical components and electronic controllers lies in "conductive connection". Through different segmented processes (spot welding, projection welding, seam welding, flash butt welding, etc.), resistance welding adapts to the structural requirements of different components, with specific applications as follows:
1. Electronic Control Units (ECU/VCU): Connection between PCB (Printed Circuit Board) and terminals, as well as between PCB and housings
2. Motor Controllers: Connection between power modules and busbars
3. On-board Sensors: Connection between precision terminals and lead wires
4. On-board Power Supplies (OBC/DC-DC): Welding of dissimilar materials at copper-aluminum joints
For the above welding processes, different types of electrodes can be selected based on the base metals to be welded:
1: Inserted electrodes
2: Tungsten-molybdenum electrodes
3: Copper alloy electrodes
(For specific electrode selection, please consult us.)
