Driven by the rapid iteration of industries such as 5G communication, automotive electronicDriven by the rapid iteration of industries such as 5G communication, automotive electronics, and precision instruments, connectors, as the core carriers of signal transmission, are upgrading towards miniaturization, high density, and high reliability. Terminals, as the core conductive components of connectors, directly determine the contact resistance, signal integrity, and lifespan of the connector through their spot welding quality. Currently, connector terminal spot welding faces industry pain points such as difficulty in narrow-pitch positioning, easy damage to heat-sensitive materials, and poor batch consistency. Traditional single-head welding equipment and continuous wave (CW) laser technology are no longer suitable for the demands of precision manufacturing. Fly Laser, with years of experience in the laser welding field, has launched the QCW dual-head laser welding machine, using quasi-continuous wave (QCW) technology as its core and combining a dual-welding-head collaborative design to provide an integrated solution for connector terminal spot welding that is "efficient, precise, and stable," reshaping the standards of terminal welding processes.
The core competitiveness of Fly laser's QCW dual-head laser welding machine stems from the deep integration of QCW technology and the dual-welding-head collaborative design, precisely addressing the core pain points of terminal spot welding. Unlike traditional CW lasers that provide continuous heating, QCW lasers use Q-switching technology to compress energy into high-peak pulse outputs, achieving peak power up to 10 times the average power. This results in "instantaneous high-intensity heating and rapid cooling," enabling deep-penetration welding of highly reactive metals like copper and aluminum while minimizing the heat-affected zone to within 0.2mm². This fundamentally prevents deformation and plating peeling of terminals and surrounding substrates caused by continuous high temperatures. The asynchronous collaborative design of the dual welding heads achieves breakthroughs in both capacity and precision. The two welding heads can be independently programmed and operate synchronously, simultaneously completing spot welding of multiple rows of terminals, increasing capacity by 80%-120% compared to single-head equipment. It also allows for differentiated collaboration between "positioning spot welding" and "enhanced spot welding," significantly simplifying the process. Combined with a high-precision motion platform and an independent CCD vision positioning system, the repeatability of both welding heads is controlled within ±0.02mm, perfectly adapting to the welding needs of high-density terminals with spacing below 0.25mm.
Addressing the challenges of welding dissimilar copper-aluminum alloy connector terminals—commonly found in copper, aluminum, and nickel-plated alloys—and the complexities of welding dissimilar materials like copper and aluminum, Fly laser's QCW dual-head laser welding machine offers a customized process system. Through precise parameter control and the synergistic effect of its dual welding heads, it achieves a dual upgrade in welding quality and reliability for terminals made of different materials. For highly elastic copper alloy terminals (such as phosphor bronze and brass), a mainstream material in consumer electronics and automotive connectors, traditional welding methods often result in joint embrittlement and excessive contact resistance due to improper energy control. Feilai optimizes the QCW pulse width (adjustable from 100-500μs) and peak power ratio, precisely controlling the molten pool depth within 0.1-0.3mm. This results in a deep, "nail-shaped" weld joint with a tensile strength exceeding 85% of the base material and a stable contact resistance below 1mΩ. Simultaneously, it prevents high-temperature oxidation and blackening of the copper, eliminating the need for subsequent polishing and ensuring stable and durable signal transmission.
For aluminum and aluminum alloy terminals, a high-melting-point oxide film (Al₂O₃) easily forms on their surface, and these materials have high thermal conductivity and a large coefficient of linear expansion, making them prone to problems such as incomplete fusion, deformation, and cracking during welding. The Fly laser QCW dual-head laser welding machine employs a "dual-pulse synergy" process. One welding head outputs a short pulse to break through the oxide film, while the other welding head uses a low-eners, and precision instruments, connectors, as the core carriers of signal transmission, are upgrading towards miniaturization, high density, and high reliability. Terminals, as the core conductive components of connectors, directly determine the contact resistance, signal integrity, and lifespan of the connector through their spot welding quality. Currently, connector terminal spot welding faces industry pain points such as difficulty in narrow-pitch positioning, easy damage to heat-sensitive materials, and poor batch consistency. Traditional single-head welding equipment and continuous wave (CW) laser technology are no longer suitable for the demands of precision manufacturing. Fly Laser, with years of experience in the laser welding field, has launched the QCW dual-head laser welding machine, using quasi-continuous wave (QCW) technology as its core and combining a dual-welding-head collaborative design to provide an integrated solution for connector terminal spot welding that is "efficient, precise, and stable," reshaping the standards of terminal welding processes.
The core competitiveness of Fly laser's QCW dual-head laser welding machine stems from the deep integration of QCW technology and the dual-welding-head collaborative design, precisely addressing the core pain points of terminal spot welding. Unlike traditional CW lasers that provide continuous heating, QCW lasers use Q-switching technology to compress energy into high-peak pulse outputs, achieving peak power up to 10 times the average power. This results in "instantaneous high-intensity heating and rapid cooling," enabling deep-penetration welding of highly reactive metals like copper and aluminum while minimizing the heat-affected zone to within 0.2mm². This fundamentally prevents deformation and plating peeling of terminals and surrounding substrates caused by continuous high temperatures. The asynchronous collaborative design of the dual welding heads achieves breakthroughs in both capacity and precision. The two welding heads can be independently programmed and operate synchronously, simultaneously completing spot welding of multiple rows of terminals, increasing capacity by 80%-120% compared to single-head equipment. It also allows for differentiated collaboration between "positioning spot welding" and "enhanced spot welding," significantly simplifying the process. Combined with a high-precision motion platform and an independent CCD vision positioning system, the repeatability of both welding heads is controlled within ±0.02mm, perfectly adapting to the welding needs of high-density terminals with spacing below 0.25mm.
Addressing the challenges of welding dissimilar copper-aluminum alloy connector terminals—commonly found in copper, aluminum, and nickel-plated alloys—and the complexities of welding dissimilar materials like copper and aluminum, Fly laser's QCW dual-head laser welding machine offers a customized process system. Through precise parameter control and the synergistic effect of its dual welding heads, it achieves a dual upgrade in welding quality and reliability for terminals made of different materials. For highly elastic copper alloy terminals (such as phosphor bronze and brass), a mainstream material in consumer electronics and automotive connectors, traditional welding methods often result in joint embrittlement and excessive contact resistance due to improper energy control. Feilai optimizes the QCW pulse width (adjustable from 100-500μs) and peak power ratio, precisely controlling the molten pool depth within 0.1-0.3mm. This results in a deep, "nail-shaped" weld joint with a tensile strength exceeding 85% of the base material and a stable contact resistance below 1mΩ. Simultaneously, it prevents high-temperature oxidation and blackening of the copper, eliminating the need for subsequent polishing and ensuring stable and durable signal transmission.
For aluminum and aluminum alloy terminals, a high-melting-point oxide film (Al₂O₃) easily forms on their surface, and these materials have high thermal conductivity and a large coefficient of linear expansion, making them prone to problems such as incomplete fusion, deformation, and cracking during welding. The Fly laser QCW dual-head laser welding machine employs a "dual-pulse synergy" process. One welding head outputs a short pulse to break through the oxide film, while the other welding head uses a low-energy long pulse to maintain the stability of the molten pool. Combined with the laser oscillation function (oscillation amplitude adjustable from 0.1-1mm) to expand the fusion area, it effectively eliminates oxide film interference, strictly controlling the heat-affected zone within 0.2mm², and ensuring terminal deformation ≤0.01mm, perfectly meeting the precision welding requirements of miniature aluminum terminals. For nickel-plated alloy terminals (such as nickel-plated copper and nickel-plated steel), the core challenge in welding is the easy burning and peeling of the plating, affecting conductivity and corrosion resistance. The equipment achieves the ideal effect of "micro-melting of the plating and deep melting of the substrate" by precisely controlling the pulse energy density (≤10⁶W/cm²) and spot welding time (≤0.3 seconds). The plating retention rate reaches over 95%, and the solder joints show no corrosion or peeling in the salt spray test (48 hours of neutral salt spray), meeting the weather resistance requirements of high-end connectors.
In copper-aluminum dissimilar terminal welding scenarios (commonly seen in automotive high-voltage connectors and energy storage connectors), the significant differences in the physical properties of the two materials easily lead to the formation of brittle compounds (CuAl₂), resulting in low joint strength. Fly laser utilizes a dual-head differential energy distribution system: high-energy pulses on the copper side ensure deep penetration, while low-energy pulses on the aluminum side reduce the formation of brittle compounds. Combined with an oscillating brazing process, the thickness of the brittle compound layer is strictly controlled to within 10μm, porosity is reduced to below 5%, and the joint tensile strength can reach over 250MPa. Even after passing the MIL-STD-883H standard vibration test (≥20G), its performance remains stable, perfectly solving the industry challenge of welding dissimilar material terminals.
In high-density, miniaturized terminal welding scenarios, the Fly laser QCW dual-head laser welding machine demonstrates strong adaptability, easily handling the spot welding needs of various complex terminal structures. As connectors are upgraded to miniaturization, terminal spacing has been compressed from the traditional 0.5mm to 0.15-0.25mm, and pin width is only 0.1mm. Traditional welding methods are prone to bridging and cold solder joints. The equipment is equipped with a coaxial vision positioning and real-time correction system, which can accurately identify terminal contours and positional deviations, dynamically adjust the welding points, and achieve a repeatability accuracy of ±5 micrometers with a six-point micro-stress positioning fixture. It can stably weld 0.15mm × 0.15mm micro-pads, completely eliminating the bridging risk of narrow-pitch terminals. For the mass production needs of multi-pin terminals, the equipment has a built-in library of over 80 dedicated process parameters for terminal spot welding. It can automatically match parameters such as pulse energy, frequency, and spot welding time according to terminal material, thickness, and spacing. The welding time for a single weld point is ≤0.3 seconds, and the yield rate is consistently above 99.95%, significantly reducing the scrap rate in mass production.
In high-end connector manufacturing scenarios such as automotive and RF, the Fly laser QCW dual-head laser welding machine has become a core piece of equipment in mass production lines due to its high stability and compliance. Automotive connectors must meet stringent operating conditions such as high temperature, vibration, and interference resistance. The equipment utilizes plasma monitoring and real-time infrared temperature measurement systems to dynamically feedback solder joint quality and automatically adjust parameters, ensuring stable performance even after MIL-STD-883H standard vibration testing (≥20G), fully meeting the reliability requirements of automotive electronics. In RF connector terminal soldering, the equipment is equipped with a nitrogen protection system (purity ≥99.99%), effectively inhibiting solder joint oxidation, optimizing solder joint morphology, reducing signal reflection and standing wave interference, and lowering insertion loss by 15%, meeting the low-loss transmission requirements of millimeter-wave band signals. The modular quick-change fixture design allows for rapid changeover within 30 seconds, adapting to the flexible production needs of different terminal specifications. Changeover time is reduced by more than 80% compared to traditional equipment, helping companies address the pain points of multi-variety, small-batch production.
As a technology leader specializing in precision welding, Fly Laser provides connector terminal manufacturers with full-cycle service support, ensuring rapid equipment deployment and efficient operation. The equipment features an intuitive touchscreen interface and a built-in dedicated process package for terminal spot welding, allowing for quick and easy operation without specialized skills. It integrates an AOI (Automated Optical Inspection) module, enabling real-time monitoring of solder joint morphology, positional deviations, and other indicators, achieving full-process control of welding quality and reducing manual inspection costs. Meanwhile, Fly boasts a professional technical team and a comprehensive after-sales network, providing one-stop services including on-site installation and commissioning, customized process optimization, and regular maintenance. For different customers' terminal specifications and production capacity needs, customized expansion solutions such as dual-station linkage and automatic loading and unloading can be implemented, achieving a daily production capacity of over 80,000 pieces, helping companies achieve cost reduction, efficiency improvement, and quality upgrades.
From automotive high-voltage connectors to RF communication connectors, from consumer electronics terminals to industrial precision connectors, Fly laser's QCW dual-head laser welding machine breaks through industry bottlenecks with technological innovation, empowering the connector industry's upgrade with precise and efficient spot welding solutions. In the new era of manufacturing pursuing "miniaturization, high density, and high reliability," Fly Laser will continue to deepen its expertise in QCW technology and dual-head collaborative processes, constantly iterating on product and process parameters to provide connector terminal manufacturers with more competitive welding equipment. Together with our customers, we will create high-end connector products and embark on a new journey of intelligent manufacturing.
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