Branched end layout分支端头布局
Conductors separate toward different ends, creating individual connection points. Branch lengths and directions can follow the equipment modules.导线向不同端头分出，形成独立接入位置。各支路可围绕设备模块分别安排长度与方向。
Ultrasonic-Welded Branch超声波焊接分支
Rectangular Main Connector Multi-Way Branch Harness矩形主接头多路分支线束
Rectangular Main Connector Multi-Way Branch Harness combines branched end layout, rectangular interface form, plug-in connection end. Interface, circuit and installation data guide dimensions, material selection and sample review.矩形主接头多路分支线束的结构重点包括分支端头布局、矩形接口外形、插接式端头。接口、电路与安装资料将作为尺寸、物料和样品制作的确认依据。
- Branched end layout分支端头布局
- Rectangular interface form矩形接口外形
- Plug-in connection end插接式端头
CONSTRUCTION结构解析
Connection structure and design details连接结构与设计要点
Use the rectangular main connector multi-way branch harness form as a starting point and confirm these design points against drawings and the actual equipment.以矩形主接头多路分支线束的结构形式为起点，结合图纸和实际设备确认以下设计要点。
Rectangular interface form矩形接口外形
The rectangular interface form allows end position and service clearance to follow the mating face, latch and cable exit.接口采用矩形轮廓，可围绕插入面、卡扣与线束出口安排端头位置和拆装空间。
Interface and function review接口与功能确认
A joint photo does not establish ultrasonic welding焊点照片不能证明超声波工艺
CONFIGURATION结构与选配
Construction & customization options结构与定制配置
The table describes the construction and available configuration choices. Materials, dimensions, circuits and inspection requirements are agreed for each project.以下说明展示结构与可配置内容。具体材料、尺寸、电路和检验要求按项目确认。
| Weld conductor material, area combination and branches焊接导体材质、截面组合与支路 | Record conductor materials, individual branch areas and the welding combination.记录导体材质、各支路截面和焊接组合。 |
|---|---|
| Joint geometry, compressed dimensions and insulation接头几何、压缩尺寸与绝缘 | Confirm joint geometry, compressed dimensions and subsequent insulation boundaries.确认接头几何、压缩尺寸和后续绝缘边界。 |
| Welder, tooling and process window焊机、工装及工艺窗口 | Match the welder, tooling and process window to the actual material combination.焊机、工装及工艺窗口须对应实际材料组合。 |
| Pull, resistance and section-inspection methods拉力、电阻及截面检查方法 | Define pull, resistance and cross-section checks for the project.按项目确定拉力、电阻及截面检查方法。 |
| Installation and operating boundary安装与使用边界 | Provide every wire material and area, circuit, branch geometry, strip and protection needs, environment, standard, quantity and validation limits.请提供每根线材与截面积、回路、分支几何、剥线和防护、环境、标准、数量与验证限值。 |
| Sample and release basis样品与放行依据 | Release records wire stack, preparation, nugget limits, tooling, machine, parameter window, protection and inspection evidence.放行文件记录线材叠放、备线、焊点限值、工装、设备、参数窗口、防护与检验证据。 |
APPLICATIONS连接的应用
Application directions应用方向
These are connection directions for project discussion. Suitability depends on interfaces, circuits, installation conditions and project validation; configuration can be adapted to the equipment.以下为可讨论的连接方向。实际适用性取决于接口、电路、安装环境和项目验证，可按设备需求调整。
Branch joining and joint protection分支汇接与接点保护
Define each conductor, stacking direction and joint geometry before selecting tooling, insulation protection and inspection methods. Record conductor materials, individual branch areas and the welding combination.分支汇接需定义每根导体、叠放方向和接头几何，再选择工装、绝缘保护与检验方法。选配时，记录导体材质、各支路截面和焊接组合。
Contact and fine-wire termination端子与细线端接
Contact selection depends on conductor construction, insulation diameter and tooling limits. Set wire preparation and crimp inspection for the actual contact part. Confirm joint geometry, compressed dimensions and subsequent insulation boundaries.端子选择同时取决于导体结构、绝缘外径和工具范围；备线尺寸与压接检查应落到实际接点型号。选配时，确认接头几何、压缩尺寸和后续绝缘边界。
Equipment power-distribution branches设备电源分配支路
Select power branches from actual loads, circuit protection and route length. Include termination, retention and service positions in the wiring definition. Match the welder, tooling and process window to the actual material combination.供电分支以实际负载、回路保护和线长为选配依据，端头、固定和检修位置也需列入布线定义。选配时，焊机、工装及工艺窗口须对应实际材料组合。
Battery and removable power connections电池与可拆电源连接
Define polarity, continuous and peak load, and permitted connection conditions. Record auxiliary signals separately from the main power path. Define pull, resistance and cross-section checks for the project.电池连接要明确极性、持续与峰值负载以及允许插拔条件，辅助信号回路与主电源路径应分别记录。选配时，按项目确定拉力、电阻及截面检查方法。
Module wiring within enclosures机箱内部的模块配线
Coordinate board positions, module removal and wire bends within the enclosure. Preserve insulation clearance and support behind each termination. Record conductor materials, individual branch areas and the welding combination.机箱内部配线需要协调板卡位置、模块拆装和导线转弯空间；端接后的绝缘与支撑不能被外壳挤压。选配时，记录导体材质、各支路截面和焊接组合。
Vehicle control-module leads车辆控制模块引线
Separate interface cavities, power circuits and signal circuits at controller leads. Set branch dimensions from the module and mounting-point positions. Confirm joint geometry, compressed dimensions and subsequent insulation boundaries.控制模块尾线需要清楚区分接口腔位、电源和信号回路；分支尺寸应对应模块与固定点的位置。选配时，确认接头几何、压缩尺寸和后续绝缘边界。
ENGINEERING & PRODUCTION工程与制造
Adapt the connection to your equipment.围绕设备，调整连接细节。
Touched by me, better it’ll beTouched by me, better it’ll be
Custom wire harness manufacturing in China中国工厂 · 定制线束制造
Our China factory supports ultrasonic-welded branch projects through custom wire harness manufacturing and OEM/ODM development. Interface, circuit and installation data guide material selection, sample builds and manufacturing-document approval before repeat production.Super Smile-Tech 中国工厂围绕超声波焊接分支的项目需求提供定制线束制造与 OEM/ODM 支持。我们从接口、电路与安装资料开始，协同物料选配、样品制作和制造文件确认，再按批准要求组织重复生产。
Define termination and protection boundaries确定端接与保护边界
Record conductor materials, individual branch areas and the welding combination. A joint photo does not establish ultrasonic welding.记录导体材质、各支路截面和焊接组合。 焊点照片不能证明超声波工艺。
Match dimensions and operating motion配合尺寸与使用动作
Confirm joint geometry, compressed dimensions and subsequent insulation boundaries. Copper/aluminum or dissimilar joints need dedicated process evidence.确认接头几何、压缩尺寸和后续绝缘边界。 铜铝或异材组合需专用工艺依据。
Verify processing and finished condition验证工艺与成品状态
Match the welder, tooling and process window to the actual material combination. Inspect joint load capability separately from insulation protection.焊机、工装及工艺窗口须对应实际材料组合。 接头负载和绝缘防护分开检验。
PRODUCT QUESTIONS产品问答
Product & customization questions产品与定制常见问题
Does a joint photograph establish ultrasonic processing?焊点照片能确认使用超声波工艺吗？
A joint photo does not establish ultrasonic welding. Record conductor materials, individual branch areas and the welding combination.焊点照片不能证明超声波工艺。记录导体材质、各支路截面和焊接组合。
Can copper-aluminium combinations use the copper-wire welding process?铜铝组合可以沿用铜线焊接工艺吗？
Copper/aluminum or dissimilar joints need dedicated process evidence. Confirm joint geometry, compressed dimensions and subsequent insulation boundaries.铜铝或异材组合需专用工艺依据。确认接头几何、压缩尺寸和后续绝缘边界。
Do weld-quality checks also define insulation protection?焊接质量检查包含绝缘防护吗？
Inspect joint load capability separately from insulation protection. Match the welder, tooling and process window to the actual material combination.接头负载和绝缘防护分开检验。焊机、工装及工艺窗口须对应实际材料组合。
Start with your interface and installation requirements从您的接口与安装需求开始
Share mating interfaces, a circuit table, target lengths or a sample for the rectangular main connector multi-way branch harness. We can use them to review configuration and sample requirements.提供矩形主接头多路分支线束的对插接口、回路表、目标长度或参考样品，我们据此梳理选配与样品确认事项。