Firstly,the paper analized of the ultrasonic welding process issues in new energy vehicle current transducer,identified the causes of welding defects as three types of failures in the plastic at the weld points. From a mechanistic perspective,the main reasons for weld point failure are related to welding process and weld seam area mechanical properties. Subsequently,research is conducted on ultrasonic welding process and injection molding shell performance,qualitatively comparing performance differences under different ultrasonic welding processes. Simultaneously,in conjunction with the actual operational conditions of the sensor and the environmental requirements of the vehicle,boundary values for weld point peel force under overall vehicle operating conditions are identified. Finally,through Design of Experiments (DOE) analysis,mechanical analysis of sensor weld points is carried out under different welding processes,evaluating the weld point morphology and peel force distribution of the product,predicting weld point performance,solidifying the optimal welding process parameters,reducing the defect rate. Validating the performance of the weld points through long-term durability testing to ensure the reliability of the current sensor throughout its lifecycle.
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