Klass.-Nr.

69 30 2 May 2005

Norm vor Anwendung auf Aktualität prüfen / Check standard for current issue prior to usage.
Ultrasonically Welded Electric Lines VW
603 07
In case of discrepancies the German version shall govern.

Konzernnorm
The English translation is believed to be accurate.

Descriptors: weld node, ultrasonic welding, electric line, line

Changes

The following changes have been made as compared to VW 603 07, 2004-04:
─ Process tolerances for node cross-sections under point 2 added.
─ Standard edited.

Previous issues
1996.11; 1998.11; 1998.04; 2002.08; 2004.10;
Contents
1 Scope .................................................................................................................................. 1
2 General requirements ......................................................................................................... 2
3 Weld node geometry ........................................................................................................... 2
3.1 Dimensions ......................................................................................................................... 2
3.2 Compression ....................................................................................................................... 3
3.3 Conductor combination and cascading ............................................................................... 3
3.4 Maximum number of conductors, distribution...................................................................... 4
4 Tests ................................................................................................................................... 4
4.1 General ............................................................................................................................... 4
4.2 Bending test ........................................................................................................................ 4
4.2.1 Test procedure .................................................................................................................... 4
4.2.2 Requirements...................................................................................................................... 4
4.3 Tensile strength test............................................................................................................ 5
4.3.1 Test procedure .................................................................................................................... 5
4.3.2 Requirements...................................................................................................................... 5
4.4 Peel strength test ................................................................................................................ 6
4.4.1 Test procedure .................................................................................................................... 6
4.4.2 Requirements...................................................................................................................... 6
4.5 Environmental testing.......................................................................................................... 7
4.5.1 Test procedure .................................................................................................................... 7
4.5.2 Requirements...................................................................................................................... 8
QUELLE: NOLIS

5 Referenced standards*) ....................................................................................................... 8

1 Scope
This standard is valid for electrical connections produced by ultrasonic welding between stranded
lines, finely stranded lines and extra finely stranded lines of Cu, designated “weld nodes” in the
following.
This standard includes requirements and tests for weld nodes.
Form FE 41 - 01.05

Page 1 of 8
Fachverantwortung/Responsibility Normung/Standards (EZTD, 1733)
EEE7 Dr. Wille Tel: +49 5361-9-22991 Just Tel: +49-5361-9-25934 Sobanski

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the B2B supplier platform “www.vwgroupsupply.com”.
 VOLKSWAGEN AG
Page 2
VW 603 07: 2005-05

2 General requirements
─ Materials and dimensions of the lines to be welded must comply with VW 603 06.
─ Individual wires that are missing, loose, squeezed off, pushed up or that project from the node
are impermissible.
─ The tool structure must be clearly recognizable on the node surface.
─ Burrs larger than the largest individual-wire diameter are impermissible.
─ Overheating of the weld node (blue discoloration) is impermissible.
─ Cracks or fractures in the weld node are impermissible.
─ The conductor insulation must not be damaged (melted) by the welding process.
─ Foreign bodies in the node are impermissible.
─ The welding of tinned lines is impermissible.
─ Process tolerances:
─ A cross-section deviation (increase/reduction, monitored via the compacting dimension)
exceeding 7% for node cross-sections up to 5 mm2 and exceeding 5% for node cross-sections
over 5 mm2 is not permissible.

3 Weld node geometry

3.1 Dimensions
All lines must be inserted in such a way that the following dimensions are observed
(Table 1 and Figure 1)

Weld zone

Figure 1 – Weld node

Table 1 – Node dimensions

A depends on tool
B ≤ 1 mm
C 3 mm ≤ 6 mm

Maximum node cross-section: 30 mm2.

 Page 3
VW 603 07: 2005-05

The node must be rectangular, with the following ratio between the width b (anvil or sonotrode side)
and the height h (see Figure 2):
5

4
Height h (mm)

0
1 2 3 4 5 6 7 8
Width b (mm)
Figure 2 – Ratio between width and height

─ The optimal ratio must be determined in tensile-strength tests.

─ All individual wires must lie in the weld zone over their entire length.

3.2 Compression
The compression of the weld node is assessed by means of a microsection. For this purpose,
the node is encapsulated in synthetic resin and a transverse section is made through the center of
the node.
─ All individual wires must be deformed and interconnected.
─ Isolated cavities between individual wires must not be interconnected.
─ The degree of compression V shall be 85 to 95%. V = 100 (AK/AL)%.
AL = Total of conductor cross sections
AK = Node width b x node height h
The optimal degree of compression must be determined in tensile-strength tests and peel-strength
tests. See Sections 4.3 and 4.4.

3.3 Conductor combination and cascading

Permitted conductor combinations are described in Table 2.
If a node does not meet the condition set above, it shall be subdivided into several nodes.
The maximum cross-section meeting the combination requirements of both nodes while
considering the permissible current load of this line shall be used for the connecting line(s).
The nodes shall not be placed next to each other but staggered at intervals of ≥ 60 mm in
the harness.
The nodes may not however be positioned in bends and branches.
Deviations are permissible only after consultation with the responsible engineering department.
Page 4
VW 603 07: 2005-05

Table 2 Conductor combinations (dimensions in mm2)

Conductor cross-section
0.35 0.50 0.75 1.00 1.50 2.50 4.00 6.00 10.00
0.35 z z z z z X X X X
Conductor cross-section

0.50 z z z z z z X X X
0.75 z z z z z z X X X
1.00 z z z z z z z X X
1.50 z z z z z z z z X
2.50 X z z z z z z z z
4.00 X X X z z z z z z
6.00 X X X X z z z z z
10.00 X X X X X z z z z
z permissible
X not permissible

3.4 Maximum number of conductors, distribution

─ A maximum of 5 lines are permitted per side for long nodes.
─ For long nodes with plastic shrink tubes, it is important to ensure that the lines are evenly
distributed on both sides of the nodes for reasons relating to leak tightness.
─ A maximum of 15 lines are permitted for end nodes.

4 Tests

4.1 General
The tests must be performed without insulating elements around the node.
A specimen must not be used for more than one test.

4.2 Bending test

4.2.1 Test procedure

The lines located in the node’s upper part shall be bent by 90° and back to their initial position twice
while the node is fixed and force is applied to the lines under test at 30 mm from the node.

4.2.2 Requirements
Individual wires must not break at the transition point to the weld zone.
Individual wires must not loosen or become detached at the node.
 Page 5
VW 603 07: 2005-05

4.3 Tensile strength test

4.3.1 Test procedure

Tensile speed: (50 + 5) mm/min
Each conductor cross-section in a node type must be checked. Nodes must be selected on which
the individual wires of the conductor to be tested lie on the anvil-side node surface.
In order to avoid shearing forces, opposite lines must be selected in such a way that the
longitudinal axis of the node is parallel with the clamped lines (Figure 3).
The cross-section of the opposite conductor must be larger than that of the conductor to be tested;
several conductors can be combined if necessary.

4.3.2 Requirements
The conductors’ extraction strengths in the weld node must reach the minimum values specified
in Table 3.

Longitudinal axis of the node

Figure 3 – Test setup for measuring extraction strength

Table 3 – Extraction strength

Nominal conductor Minimum extraction
cross-section (mm2) strength (N)
0.35 60
0.5 80
0.75 120
1.0 160
1.5 200
2.5 250
4.0 350
6.0 400
10.0 500
Page 6
VW 603 07: 2005-05

4.4 Peel strength test

4.4.1 Test procedure

Tensile speed: (50 + 5) mm/min
All conductor cross-sections of a node type must be checked.
Test setup, see Figure 4.
Nodes must be selected on which the individual wires of the conductor to be tested lie on the anvil-
side node surface.
The cross-section of the second conductor must be larger than that of the conductor to be tested;
several conductors can be combined if necessary.

4.4.2 Requirements
The conductors’ peel strength in the weld node must reach the minimum values specified
in Table 4.

Longitudinal axis of the node

Figure 4 – Test setup for measuring peel strength

Table 4 – Peel strength

Nominal conductor Minimum peel
cross-section (mm2) strength (N)
0.35 12
0.5 15
0.75 23
1.0 35
1.5 45
2.5 70
4.0 100
6.0 130
10.0 150
 Page 7
VW 603 07: 2005-05

4.5 Environmental testing

4.5.1 Test procedure

Carry out the test sequence below:
1. Voltage drop test in initial condition acc. to Section 4.5.1.4
2. Temperature shock acc. to Section 4.5.1.1
3. Humid heat test acc. to Section 4.5.1.2
4. Temperature test acc. to Section 4.5.1.3
5. Voltage drop test after aging acc. to Section 4.5.1.4

4.5.1.1 Temperature shock

144 cycles
1 cycle: 15 min. at - 40 °C and +135 °C, respectively; acclimatization period 10 s

4.5.1.2 Humid heat test

7 cycles according to DIN 50017 FKW environmental cycle test (humidity)

4.5.1.3 Temperature test

168 h storage at 105 °C in forced-air furnace

4.5.1.4 Voltage drop

The voltage drop is measured and calculated as shown in Figure 5.
The test current is 5 A/mm2; if the cross-sections differ, the value for the smaller one shall be used.
The voltage drop across the node is calculated by subtracting the individual voltage drops of the
conductors between points A/B and C/D from the total voltage drop between A/D.

Figure 5 – Test setup for measuring voltage drop

Page 8
VW 603 07: 2005-05

4.5.2 Requirements
The voltage drop must not exceed the values specified in Table 5.

Table 5 – Voltage drop across the node

Voltage drop (mV)
at (1 A) test current
Initial condition 0.5
After aging 1.5

5 Referenced standards*)
DIN 50017 Atmospheres and their Technical Application; Condensation Water
Test Atmospheres
TL 823 24 Shrink Tubes; Functional Requirements
VW 603 06 Low-Voltage Cables in Motor Vehicles; Single-Wire, Unshielded,
Requirements and Tests

*)
In this section, terminological inconsistencies may occur as the original titles are used.