Double Sided Automatic Spot Welder for Lithium Ion Battery Pack Production

Product Overview

This system is a high-precision automatic double-sided resistance spot welding solution for joining nickel strip to cylindrical lithium-ion cell terminals. It combines AI-assisted inspection, industrial motion control, synchronized welding capability, and programmable process management to help manufacturers produce consistent battery interconnects at scale. Single-side or double-side welding can be completed in one operating cycle, supporting stronger joints, higher throughput, and repeatable pack quality.

The equipment is designed for power battery modules and packs, energy-storage battery packs, power-tool batteries, and consumer battery production. It supports steel-cased cylindrical cells and nickel materials including pure nickel, nickel-plated strip, and copper-nickel composite strip. Flexible axis travel, DXF-based path generation, and configurable welding recipes allow it to serve varied fixture layouts and pack architectures.

Built for demanding production environments, this unit combines servo-driven positioning, water-cooled welding electrodes, monitored power output, and fault alarms to maintain process stability. Its optional manufacturing data functions support traceable, digitally managed production where welding records can be retained, reviewed, and integrated with plant systems.

Key Features

• Synchronized Double-Sided Welding: Independent dual X-axis operation and independently rotating dual R axes enable coordinated welding on one or both sides. The configuration reduces handling steps and helps manufacturers increase output while maintaining joint consistency.

• High-Output Transistor Welding Power: The supported transistor power configuration provides up to 12,000 A bidirectional welding capability. Controlled current ramp-up and ramp-down help create smoother weld nuggets and support a more stable connection process.

• Precision Servo Motion Platform: Servo-controlled X, Y, R, and Z axes provide positioning accuracy of plus or minus 0.02 mm. The motion system is engineered for repeatable electrode placement across dense battery layouts and extended production cycles.

• AI-Assisted Setup Verification: Automated functions correct the detected length of the welded item, check spot-welding electrode length error, and detect welding limit positions. These functions reduce setup uncertainty and help limit errors associated with manual judgment.

• Adaptive Contact Motion: Two-stage welding motion runs quickly to the programmed position and then slows before the electrode contacts the nickel strip and cell. This controlled approach helps prevent cell indentation and leakage caused by unsuitable contact conditions.

• Real-Time Welding Process Monitoring: The system automatically detects output current and voltage, with alarms for undercurrent, undervoltage, and welding spark events. Current welding parameters are displayed in real time and stored locally for process review.

• DXF-Based Welding Programming: Operators can import DXF files to generate welding parameters automatically, then use array or block-array programming to define the weld pattern. Unneeded locations can be removed manually after array generation for practical fixture-level adjustment.

• Production Recovery Controls: Zone welding allows operators to specify a defined point range, while breakpoint continuation enables welding to resume from a selected interrupted position after a fault is cleared. These functions help reduce lost work during production interruptions.

• Water-Cooled Electrode System: A dedicated chiller provides circulating water cooling at approximately 6 L/min and below 20 degrees. This thermal management supports electrode condition and welding consistency during high-frequency operation.

• Scalable Digital Manufacturing Options: Optional MES and SCADA communication, local spreadsheet data storage, pressure sensing, and barcode-driven operation support traceability requirements for advanced battery pack manufacturing environments.

Applications

Technical Specifications

Optional Custom Functions

Why Choose This Product

• Production-Focused Mechanical Precision: Servo-driven multi-axis control, controlled electrode movement, and plus or minus 0.02MM positioning accuracy provide a dependable foundation for repeatable battery interconnect welding.

• Built for Process Consistency: Current and voltage monitoring, alarm protection, controlled current transition, cooling, and programmable electrode pressure support stable operation across demanding production schedules.

• Digital Traceability Capability: Local parameter retention and optional Web/API production-data upload provide a practical route toward connected MES and SCADA manufacturing workflows.

• Flexible for Evolving Pack Designs: Support for multiple cylindrical cell sizes, nickel-strip configurations, fixture dimensions, DXF programming, and more than 1000 stored recipe groups helps protect the equipment investment as products change.

• Premium Manufacturing Assurance: CE certification, industrial PC and PLC control, AI-assisted verification, and configurable barcode and pressure-detection options support disciplined, quality-focused battery pack production.

Contact us for a quote or a custom solution configured for your battery cell format, fixture design, production throughput, and data-traceability requirements.

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