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GS 95006-3:2024-01

BMW Group Standard Released GS 95006-3

2024-01

Replacement for
GS 95006-3:2023-08

Wiring harnesses in motor vehicles

Ultrasonically welded joints of stranded wires

Requirements, tests

Edited by
Martin Ruppel, Standardization

Print-outs are not subject to the change service.

The user of this document is under obligation to verify its current validity.

Continued page 2 to 15
© BMW Group - All rights reserved
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GS 95006-3:2024-01
Contents

1 Scope and purpose ............................................................................................................................................. 3

2 Normative references ......................................................................................................................................... 3
3 Abbreviations, terms and definitions ................................................................................................................ 4
3.1 Abbreviations....................................................................................................................................................... 4
3.2 Terms ................................................................................................................................................................... 4
3.3 Definitions ............................................................................................................................................................ 4
3.4 Symbols ................................................................................................................................................................ 4
4 Designation .......................................................................................................................................................... 4
5 Description of the technology ............................................................................................................................ 5
6 Requirements for welding equipment ............................................................................................................... 6
7 Process monitoring ............................................................................................................................................. 6
8 Design requirements for weld nodes ................................................................................................................ 6
8.1 Positioning of splice connectors ........................................................................................................................ 6
8.2 Requirements for the conductor ........................................................................................................................ 6
8.3 Requirements for the connector ........................................................................................................................ 7
9 Specifications for processing ............................................................................................................................. 9
10 Quality validation tests for splicers ................................................................................................................ 10
10.1 Non-destructive tests parallel to production ................................................................................................. 10
10.2 Destructive testing ........................................................................................................................................... 13
11 Quality criteria .................................................................................................................................................. 15
11.1 General information ......................................................................................................................................... 15
11.2 Frequency of checking quality criteria............................................................................................................ 15
11.3 Capability studies ............................................................................................................................................. 15

Foreword

The German version is binding.

The reproduction, distribution and utilization of this document as well as the communication of its contents to others
without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights
reserved.

This Group Standard has been coordinated with the responsible departments of the BMW Group. The names of the
persons creating, releasing and checking this Group Standard are filed and can be retrieved in the master data of
the TEREG system.

Amendments

The following amendments have been made to GS 95006-3:2023-08:

− section 3.1 updated;

− section 8.3.4 updated.
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GS 95006-3:2024-01

Previous editions

BMWN(S) 60124.0 T(P)3:1993-10, 1994-07, 1999-11

GS 95006-3: 2000-04, 2009-01, 2014-03, 2021-04, 2023-08

1 Scope and purpose

This Group Standard applies for wiring harnesses in vehicles. It describes the uses of ultrasonic welding to produce
non-losable fastenings between multiple stripped stranded wires. This Group Standard provides a binding
specification of the requirements and quality criteria between BMW and the wiring harness manufacturer.

2 Normative references

This Group Standard incorporates provisions from other publications. These normative references are cited at the
appropriate places in the text and the publications are listed hereafter. The respective latest edition of the
publication is applicable.

GS 95006-1 Wiring harnesses in motor vehicles; Requirements, tests

GS 95006-7-1 Wiring harnesses in motor vehicles; Plug connectors; Tests
GS 95007-1-1 Low tension cables for motor vehicles; Copper cables single-core, unscreened;
Requirements, tests
GS 95007-1-1 BBL1 Low voltage cables for motor vehicles; Media list
GS 95007-1-2 Low tension cables for motor vehicles; Aluminium cables single-core, unscreened;
Requirements, tests
GS 95007-1-3 Low voltage cables for motor vehicles; Determination of the ampacity of motor vehicle
cables
GS 95007-1-4 Low voltage cables for motor vehicles; Cables made of copper alloy, single core,
unscreened; Requirements, tests
GS 95007-1-5 Low tension cables for motor vehicles; Twisted and stranded cables; Requirements, tests
GS 95007-1-5 BBL1 Low voltage cables for motor vehicles; Twisted and stranded cables; Quality and process
requirements
GS 95008-5 Wiring harnesses components in motor vehicles; Longitudinal and splice seals;
Requirements, tests
QV 11739656 Watertight seal along wiring harnesses
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3 Abbreviations, terms and definitions

3.1 Abbreviations

QMT Quality management parts

3.2 Terms

Ultrasonic welding Welding process in which ultrasonic oscillations are applied to the joining partners under
pressure. The frictional heat generated between the joining partners results in welding in
a solid state, i.e. none of the joining partners is melted. As a result, the material changes
as a result of the welding process are very small, and a very wide range of material pairings
are possible for this process, provided that the weld partners each have sufficient strength.

3.3 Definitions

There are no definitions in this document.

3.4 Symbols

A0 actual cross-section
Am cross-section of a single conductor
Ami cross-section of the single conductor i
As resulting cross-section
b measured width
Cm machine capability (deviation of the measurand)
Cmk critical machine capability (mean value of the measurand relative to the tolerance limit)
dm diameter of the single conductors
h measured height
n number of individual conductors
nm number of single conductors
Q degree of compaction

4 Designation

The drawing entry is made in the area provided for specifying the material or on the drawing.

Ultrasonic welding of stranded wires according to GS 95006-3

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5 Description of the technology

Ultrasonic welding is a welding technology in which a high-frequency relative motion (approx. 20 kHz) under
pressure is used to join two or more joining partners to form a material bond.

The setup of the welding system, and the essential sequence of the joining process is realized in Table 1:

Table 1: Joining processes and welding equipment

Insert Compact Weld Remove

Legend:
1 joining partner
2 anvil
3 anvil plate
4 sideshift
5 sonotrode
6 splice

The joining partners (1) are inserted in the welding system. Then the tools close; the anvil (2) compacts the joining
partners. The anvil presses against the sonotrode (5), which moves back and forward at a high frequency. This
creates a bonding area (6) that offers both high strength and very good electrical conductivity.

Structural changes of the basic material only occur in the homogeneous welding zone. There are no material
changes outside the joining area, so that the material properties of the joining partners remain unchanged.

The welding quality is significantly influenced by the materials of the joining partners and by any impurities present
on the surface of the joining partners.

The mechanical properties of a splice connection may be influenced in particular by the setup of the splice node.
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6 Requirements for welding equipment

The welding equipment shall be such that, in conjunction with the process sequences defined by the assembler,
the production of splice nodes is possible within the defined capability specifications, and the nodes meet the
requirements of section 10.

The welding system shall be checked for functional capability by authorized personnel at regular intervals. It is
mandatory to check the tool condition every time the tool is changed, at the latest after every 50 000 welds.

After a tool change, the machine shall be changed over according to the manufacturer's instructions. Proper setup
shall be demonstrated by welding sample parts. The details shall be determined by the assembler with the
responsible Quality Management Parts specialist department.

Repairs and maintenance work may only be carried out by trained and authorized personnel. In case of repairs only
original replacement parts are permissible. The relevant specifications of the welding system manufacturer shall
be observed.

The function of the integrated quality monitoring system shall be checked at regular intervals or after an extended
period of non-use. Known, repeatable defects shall be simulated. The details shall be determined by the assembler
with the responsible Quality Management Parts specialist department.

7 Process monitoring

Process monitoring shall be designed such that weld defects are reliably detected. Potential defects may include:

− insert placing errors;

− exceeding limit values for the welding time or compaction value.

Further defects may also occur. However, the equipment and processes shall ensure that no defectively welded
node may be further processed.

8 Design requirements for weld nodes

8.1 Positioning of splice connectors

The minimum clearance of an ultrasonic splice to a contact part shall be defined by the contact part manufacturer
according to GS 95006-7-1.

If no minimum clearance is defined between the contact part and the welded joint, it shall be at least 500 mm. After
the welding process, there shall be no functionally relevant damage to the contact. The cable harness assembler
shall take appropriate measures to ensure that no impermissible welding energy is transferred to the contact.

8.2 Requirements for the conductor

Only released conductors according to GS 95007-1-1, GS 95007-1-1 BBL1, GS 95007-1-2, GS 95007-1-3,

GS 95007-1-4, GS 95007-1-5 and GS 95007-1-5 BBL1 shall be processed.

Tin-plated conductors shall not be ultrasonically welded.

The storage conditions for unprocessed yard goods are defined in GS 95006-1. The storage time of previously pre-
cut goods shall not exceed 8 weeks.

The splice protection (= partial removal of the insulation) may only be removed immediately before the welding
operation.
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8.3 Requirements for the connector

8.3.1 General specifications

Ultrasonic welding connectors shall preferably be designed as end connectors.

For effective tension relief, the tap on the cable run shall preferably be tied back to the side with the smaller cable
cross-sections or designed as a connector junction.

During further processing in the wiring harness and in vehicle assembly, the weld shall not be exposed to tensile or
bending loads.

Symmetrical node structures shall be avoided as a matter of principle.

8.3.2 End connectors

No more than 8 single conductors shall be welded together.

The total cross-section of the conductors to be welded shall not exceed 20 mm².

The cross-section ratio between the largest and the smallest conductor cross-section within a node shall not
exceed 3:1 (see Table 2).

Deviating from this, the combination of 0,75 mm² with 2,50 mm² is permissible.

Table 2: Cross-section combinations

Nominal cross-section in mm²

0,13 0,17 0,35 0,50 0,75 1,00 1,50 2,50 4,00 6,00 10,00

0,13 X X X X

0,17 X X X X
Nominal cross-section in mm²

0,35 X X X X

0,50 X X X X
0,75 X X X (X)
1,00 X X X
1,50 X X X

2,50 X X X
4,00 X X X
6,00 X X
10,00 X

NOTE 1 For conductors with a cross-section of 0,13 mm² and 0,17 mm², nodes with a maximum of seven
conductors are permissible. A node with a total cross-section < 0,51 mm² is impermissible.

NOTE 2 To meet a sufficient weld quality, filling pieces are permitted in the interior.
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8.3.3 Longitudinal connectors

No more than 5 single conductors are permissible per side.

The total cross-section of the conductors to be welded shall not exceed 20 mm².

The ratio of the conductor cross-section left/right shall not exceed 2:1 or 1:2.

No longitudinal connectors are permissible for conductors of 0,13 mm² and 0,17 mm².

8.3.4 Free conductor length

The free conductor length x between the start of the weld and the end of the insulation shall be 3 mm ≤ x ≤ 6 mm
for sealed connectors and 1 mm ≤ x ≤ 3 mm for unsealed connectors (see Figure 1).

Figure 1: Free conductor length

8.3.5 Insulation of the connector

8.3.5.1 Non water-tight insulation

The welded connectors shall be insulated with internally coated shrink caps, internally coated shrink tubing or
ultrasonically welded plastic caps.

Wrapping tape may only be used for the insulation of ground connectors. Only coated fabric tape is approved, of
which ≥ 3 winding layers shall be applied. It is essential to ensure that no protruding wires pierce the tape. When
using winding tape, the dimension of 2 tape widths shall be wound on the conductor insulation; the conductor
insulation shall be covered by an excess of ≥ 12 mm.

8.3.5.2 Water-tight insulation

Water-tight connectors shall be designed according to GS 95008-5 and QV 11739656.

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9 Specifications for processing

The conductors shall be aligned straight and parallel to each other. Smoothing the strand ends with the fingers is
not permitted. Absolute cleanliness shall be ensured, especially with regard to the wire ends to be welded.

The bare wire ends of the conductors to be welded shall be adjusted to the same length by a suitable method;
positioning devices may be used for this purpose.

It shall be ensured that no single conductors are protruding. If needed, optical monitoring systems shall be used.

The degree of compaction shall be adjusted such that an optimum of electrical and mechanical properties is
achieved. This is typically the case at a compaction of (86 to 96) % (relative to the actual cross-section) (see
Figure 2).

optimum area
Tensile strength

50 60 70 80 90 100 110 120

Degree of compaction Q in %
Figure 2: Relationship between degree of compaction and tensile strength
The nodes shall be insulated in the work step that follows welding.
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10 Quality validation tests for splicers

10.1 Non-destructive tests parallel to production

10.1.1 Visual inspection

All nodes produced shall be pass through 100 % visual inspection.

The nodes shall be tested in particular with a view to the defect patterns in Table 3

Two single wires may be disconnected in the total cross-section. Protruding single wires are impermissible.

Table 3: Processing defects

Implementation: through node Implementation: end node Description

Good part

stranded wire too far

outside

insulation in the node

protruding single
conductors

single stranded wire(s)

too long

Buff formation on the edges is only permissible if:

− height of burr < 0,5 mm;

− width of burr < 0,2 mm.
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10.1.2 Dimensioning

Compliance with the free conductor length shall be tested for; see section 8.3.4.

The node width and node height shall be measured. The following tolerances are permissible:

perm. tolerance of the node width w: ±0,05 mm

perm. tolerance of the node height h for a total cross-section of ≤ 8 mm²: ±0,10 mm
> 8 mm²: ±0,15 mm
The node height is measured across at least two wave peaks.

As a general rule, attention shall be paid to not measuring the burr.

node width
w

node height
h

l > 2 mm
Figure 3: Node dimensioning

10.1.3 Check of width/height relationship

The relationship between the width and height of the welded node shall be 1:1 (for nodes ≤ 0,7 mm²) and 2:1 (for
total cross-sections > 0,7 mm²).

In addition to this, the manufacturer's specifications for the total cross-section shall be observed.
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10.1.4 Determining the degree of compaction

The degree of compaction serves for the basic acceptance and/or for requalification of machines.

The cross-section (Am) of each single conductor shall be calculated by measuring the diameter (d) and counting the
single conductors (n) according to the equation (1):

2
dm (1)
Am = nm · 4 · 3,14

Where:

Am is the cross-section of a single conductor;

dm is the diameter of the single conductors;
nm is the number of single conductors.

The actual cross-section (A0) of the node to be welded results from the total of the individual cross-sections:

A0 = ∑Ami (2)
i=1

Where:

A0 is the actual cross-section;

Ami is the cross-section of the single conductor i;
n is the number of individual conductors.

From the measured width (w) and height (h) of the welded node, the resulting cross-section As may be calculated;
see the equation (3). To take account of the surface structure/profile form, 0,2 mm are deducted from the measured
height; see the equation (3). This also determines the compaction in the troughs of the wave structure. If profiles
that deviate from the standard profiles are used, deviating profile heights may also be deducted.

As = b · (h - 0,2) (3)
Where:

As is the resulting cross-section;

w is the measured width;
h is the measured height.

Determining the degree of compaction (Q):

 A0
Q = 100 · A  % (4)
 s

Where:

A0 is the actual cross-section;

As is the resulting cross-section;
Q is the degree of compaction.

The degree of compaction (Q) should be in the range 86 % < Q < 96 %. Achieving the mechanical requirements
and meeting the electrical function is decisive.
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10.2 Destructive testing

10.2.1 General information

Welded nodes that are exposed to the stresses described in the following no longer comply with the specified
condition and shall be sorted out. Further processing is not permissible.

10.2.2 Bending test

During the bending test, the conductor(s) that lie at the top is/are bent up twice through 90° and back to the starting
position. The force is applied to the conductor to be tested at a distance of 30 mm from the weld node.

No wires may be pulled off by this stress.

10.2.3 Tensile test

To check the node strength in the tensile test, the weld node to be tested shall be implemented as a longitudinal
connector.

The weld node shall be clamped such that the peeling force component in the tensile test is minimal and that the
measured values are repeatable.

Test device:

− tensile testing machine.

Test conditions:

− speed 50 mm/min;
− axial tensile load on the welded joint;
− the conductor with the greatest cross-section is used for attachment on the opposite side;
− the conductor with the smallest cross-section is pulled.

At least the values from Table 4 shall be achieved.

Table 4: Minimum tensile strength as a function of the conductor cross-section

A in mm² 0,13 0,17 0,35 0,50 0,75 1,00 1,50 2,50 4,00 6,00 10,00

F in N 50 50 50 70 110 160 200 250 350 500 700

Statistical validation: see section 11.3.

10.2.4 Peel test

The conductor with the lowest ultrasonic penetration shall be peeled out of the welded node (conductor horizontal
on the anvil side). Only the conductors that lie at the top of the node are tested.

Test device:

− tensile testing machine.

Test conditions:

− speed 50 mm/min;
− radial tensile load on the welded joint;
− the conductor with the greatest cross-section is used for attachment on the opposite side;
− the peel strength of the conductor lying at the top of the node is determined.
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At least the values from Table 5 shall be achieved.

Table 5: Minimum peel strength as a function of the conductor cross-section

A in mm² 0,13 0,17 0,35 0,50 0,75 1,00 1,50 2,50 4,00 6,00 10,00

F in N 5 7 12 15 23 35 45 70 100 130 165

Statistical validation: see section 11.3.

10.2.5 Transverse section

The transverse section is a laboratory test that serves to gain fundamental knowledge related to the welding at the
contact areas between the single conductors.

The contact areas and their welding shall be evaluated in the transverse section. In particular, it shall be assessed
whether a homogeneous connection is made between the single conductors along the energy impact direction at
the contact surfaces. Small cavities should exist between them (see Table 6, medium compaction).

Fulfillment of the mechanical requirements under 10.2.2, 10.2.3 and 10.2.4 are decisive.

When creating the micrograph, attention shall be paid to laying the sectional view in a wave trough (location of
highest compaction).

Table 6: Micrograph ultrasonic splice

Low compaction Medium compaction High compaction

− all single conductors − tendency for overwelding

− tendency for underwelding
deformed and connected to − honeycomb shaped structure
− single conductors not
each other of single conductors
deformed in part
− small cavities between the − no cavities between the
− spot contact between single
contact surfaces contact surfaces
conductors
− large gaps between single
conductors
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11 Quality criteria

11.1 General information

The employees working on the ultrasonic welding machines shall be equipped with the necessary technical
knowledge of ultrasonic welding and, in particular, shall be familiarized with the mode of functioning of the quality
monitoring systems and processes.

11.2 Frequency of checking quality criteria

The validation tests described in section 10 are random sample inspections. The assembler defines the random
sample scope, the frequency and responsibility in consultation with Quality Management Parts specialist
department.

11.3 Capability studies

The equipment manufacturers shall provide evidence of the machine capability and gauge capability of the
measuring unit and hand it over to the user. The assessment of machine capability shall be made by evaluating the
peel test of critical weld nodes.

Test parameter: Peel strength

Machine capability parameters: Cm, Cmk ≥ 1,0
The plant operator shall be able to demonstrate process capability at all times. The required tests (peel or tensile
test and visual inspection) and records shall be provided and evaluated on an ongoing basis.