Ring-terminal end环形端子端头
A ring-terminal end provides a mounting-hole connection. Lead direction, support and insulation coverage can follow the stud position.末端采用带安装孔的环形端子形式，可围绕螺柱位置安排接线方向、端头支撑与绝缘覆盖。
Ultrasonic-Welded Branch超声波焊接分支
Ring- and pin-terminal wire harness set环形端子与针形端子连接线束组
Ring- and pin-terminal wire harness set combines ring-terminal end, end transition layout, terminal connection section. Interface, circuit and installation data guide dimensions, material selection and sample review.环形端子与针形端子连接线束组的结构重点包括环形端子端头、端头转接与组合、端子接入部位。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。
- Ring-terminal end环形端子端头
- End transition layout端头转接与组合
- Terminal connection section端子接入部位
CONSTRUCTION结构解析
Connection structure and design details连接结构与设计要点
Use the ring- and pin-terminal wire harness set form as a starting point and confirm these design points against drawings and the actual equipment.以环形端子与针形端子连接线束组的结构形式为起点，结合图纸和实际设备确认以下设计要点。
End transition layout端头转接与组合
The assembly organizes a transition or combined connection, with end directions, transition sections and fixing arranged around the equipment positions.组件以转接或组合形式组织连接，可围绕两端设备位置安排端头方向、过渡段与固定。
Grouped cable-set form组合线组形式
Several connection pieces are organized as a cable set, allowing each section to be assigned and identified by assembly sequence and module.多段连接件以线组形式组织，可按装配顺序和设备模块划分各段用途与标识。
Current path and end termination载流与端部连接
Select conductors and terminations from continuous and peak loads, installed length and temperature rise. Confirm the end interface, contact surface, insulation coverage and fixing as a set; check mounting-bore size where ring terminals are specified.依据持续与峰值负载、安装长度和温升要求选择导体与端接；端部接口、接触面、绝缘覆盖及固定方式需要成套确认；仅在采用环形端子时核对安装孔径。
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 ring- and pin-terminal wire harness set. We can use them to review configuration and sample requirements.提供环形端子与针形端子连接线束组的对插接口、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。