Choosing an ultrasonic wire welding machine starts with the wire material, joint design and conductor range—not generator power alone. RS Automation’s RSM-UWM-2042, RSM-UWM-2060 and RSM-UWM-2080 provide three options with different published cable ranges. This guide compares their specifications and explains what to check before requesting a quotation.
Compare the three ultrasonic wire welding machines
| Specification | RSM-UWM-2042 | RSM-UWM-2060 | RSM-UWM-2080 |
|---|---|---|---|
| Published cable range | 0.5–10 mm² | Within 30 mm² | 25–70 mm² |
| Rated power | 4200 W | 5000 W | 8000 W |
| Frequency | 20 kHz | 20 kHz | 20 kHz |
| Listed wire materials | Copper / aluminum | Copper / aluminum | Copper / aluminum |
| Listed welding time | Within 0.6 s | 0.5–2 s | 0.5–2 s |
| Air supply | 0.2–0.8 MPa | 0.2–0.8 MPa | 0.2–0.8 MPa |
| Electrical supply | AC 220 V, 50 Hz, single phase | AC 220 V, 50 Hz, single phase | AC 220 V, 50 Hz, single phase |
| Weight | 60 kg | 80 kg | 80 kg |
These figures are taken from the product specification tables. The pages do not define whether “cable range” refers to an individual conductor or the total conductor cross-section at the joint. Confirm this with RS Automation for your wire combination. Listed welding time should not be treated as the complete workstation cycle time, which also includes loading, positioning and unloading.
RSM-UWM-2042: an option for the listed 0.5–10 mm² range
The RSM-UWM-2042 ultrasonic wire welding machine is rated at 4200 W and lists a cable range of 0.5–10 mm². It is a starting point for evaluating joints that fall within this published range.
Prepare representative wire samples and a joint drawing before selecting tooling. For multi-wire splices, provide the number and cross-section of every conductor rather than describing only the largest wire. Confirm the required weld dimensions and inspection criteria during the sample evaluation.
RSM-UWM-2060: evaluate applications within the listed 30 mm² limit
The RSM-UWM-2060 ultrasonic wire welding machine is rated at 5000 W, with a published cable range described as “within 30 mm².” Its specification table does not give a minimum cross-section, so small-wire suitability should be checked explicitly.
This model can be considered when your proposed joint falls within the stated upper limit. Selection still depends on the wire construction, material, joint geometry and tooling. Where its range overlaps another model, compare trial-weld results and workstation requirements rather than assuming that higher power produces a better connection.
RSM-UWM-2080: an option for the listed 25–70 mm² range
The RSM-UWM-2080 ultrasonic wire welding machine has an 8000 W rating and a published cable range of 25–70 mm². It is the model to evaluate among these three when the required joint is above the other models’ stated ranges, subject to confirmation of how the range is defined.
For larger conductor assemblies, include the available weld space, cable positioning requirements and access around the joint. Check the proposed fixture and tooling with actual production samples before finalizing the equipment configuration.
Shared controls and material considerations
All three product pages describe digital control with automatic frequency compensation, matching between the generator and converter, and adjustable welding width and height. These features support process setup; they do not establish a guaranteed pull force or electrical performance for every joint.
Copper and aluminum wire are listed for all three models. This does not by itself confirm suitability for mixed copper-to-aluminum joints, plated conductors or every alloy. Specify the exact materials and coatings during the application review.
What to send before ordering
Provide the wire material, strand construction, conductor sizes, number of wires, strip length and joint drawing. Add the target weld dimensions, required mechanical and electrical acceptance criteria, expected output and available power and compressed air.
Request sample welding using the proposed tooling. Review the resulting joint against your own application requirements and confirm the machine configuration, delivery schedule and quotation before ordering.
Request an ultrasonic wire welding machine recommendation
Use the linked product pages to review each model, then contact RS Automation with your wire specifications and joint requirements. A review of the actual assembly will help determine whether RSM-UWM-2042, RSM-UWM-2060 or RSM-UWM-2080 is the appropriate candidate for testing.
