Intelligent 2600W Ultrasonic Battery Welding Machine for 10 to 25 Layer Electrode Tabs

Product Overview

This intelligent ultrasonic battery welding system is engineered to create dependable metal-to-metal connections between battery tabs, strips, and electrode foils. Its 2600W ultrasonic output, 24KHZ operating frequency, CPU control, and full-bridge regulated circuit are designed to maintain constant vibration amplitude while automatically tracking frequency. The result is a controlled welding process that supports strong joints, low internal resistance, and consistent weld appearance without manual frequency adjustment.

The equipment is suited to lithium battery cell production, battery research laboratories, pilot lines, electrode-tab processing, and advanced materials development. It supports aluminum strip to aluminum foil and nickel strip to copper foil welding configurations, making it relevant to electrode assembly processes where layered foil stacks require secure, repeatable tab attachment. Its supported weld-point formats also allow the operator to match the process to strip width, foil stack, and cell design requirements.

Built for demanding repeated operation, this unit combines a high-hardness high-speed steel welding head with a selected imported special mold-steel lower anvil. The robust mechanical structure is intended to provide stable high-frequency displacement amplitude, consistent ultrasonic output frequency, and resistance to wear and elevated process temperatures. Integrated self-diagnostics, parameter monitoring, alarms, and automatic amplitude compensation provide added process confidence during production and development work.

Key Features

• Full-Bridge Constant-Amplitude Output: The optimized full-bridge regulated circuit is designed to maintain constant vibration amplitude throughout the welding cycle. Automatic frequency tracking eliminates the need for manual frequency adjustment and helps the system sustain stable ultrasonic energy delivery as process conditions change.

• Intelligent Multi-Mode Process Control: CPU-based control supports time, energy, power, energy, and depth operating modes. This provides process teams with several ways to establish a welding recipe according to material combination, foil stack, joint geometry, and internal quality requirements.

• Stable 24KHZ Ultrasonic Operation: The controlled ultrasonic output operates at 24KHZ and is designed for strong, stable mechanical high-frequency displacement amplitude. This stable vibration behavior is important when processing delicate electrode foils that require sufficient bonding action without avoidable damage.

• Long-Life Precision-Ground Welding Head: The welding head is manufactured from imported high-speed alloy steel with high hardness. Its patterned working surface is produced through high-precision grinding, supporting a service life of more than 100,000 operations on one side and helping maintain repeatable contact characteristics over extended use.

• Wear-Resistant Lower Anvil Construction: The ultrasonic lower electrode uses selected imported special mold steel chosen for wear resistance, high-temperature resistance, toughness, and high mechanical rigidity. Controlled heat treatment is intended to limit deformation, supporting output-frequency consistency and stable mechanical transmission.

• Controlled Weld Quality for Layered Foils: The equipment is designed to produce firmly bonded joints with low internal resistance. The stated weld result aims to avoid false welding, powder vibration, separator burning, insulation-tape heating, cracked tabs or electrode sheets, surface wrinkles, and rear-side raised burrs.

• High Residual Weld Interface Coverage: Metal-to-metal residual welding surface can exceed 80%. Clear, full weld points and a flat finished surface support a reliable connection profile, while destructive tensile testing can be used to assess strength according to layer count, material type, and thickness.

• 4.3-Inch Bilingual Touchscreen Interface: A 4.3-inch anti-interference touch display provides Chinese and English operation. Operators can set trigger time, welding time, power, and secondary-wave delay time, while real-time frequency and welding power displays help maintain visibility of the active process.

• Automatic Start-Up Self-Inspection: At power-on, the system scans welding-system parameters and displays them in real time. When a fault is detected, the unit provides an alarm prompt to help prevent operation under abnormal equipment conditions.

• Weld-Data Quality Assistance: Real-time welding data can be used to establish upper and lower parameter limits for each product. When measured conditions deviate outside the configured limits, the equipment issues an alarm, enabling practical monitoring of weld consistency across repeated parts.

• Automatic Amplitude Compensation: The system automatically adjusts amplitude output to improve output stability. This compensation function supports more consistent welding behavior and helps maintain weld-quality consistency as the operating process proceeds.

• Application-Focused Weld Point Formats: Supported 3 x 3 mm, 3 x 4 mm, and 3 x 8 mm weld points give process engineers defined options for matching the joint area to battery tab and foil requirements. The available formats support both aluminum-foil and copper-foil tab-welding applications.

Applications

Technical Specifications

Why Choose This Product

• Engineered for stable ultrasonic joining: Constant-amplitude output, automatic frequency tracking, and automatic amplitude compensation are designed to maintain consistent process behavior without manual frequency adjustment.

• Built around durable working components: A precision-ground high-speed alloy-steel welding head and a tough, wear-resistant special mold-steel lower electrode support long-term mechanical stability in repeated welding work.

• Designed for measurable weld control: Real-time frequency and welding-power display, start-up self-inspection, fault alarms, and configurable quality limits provide practical visibility into each welding process.

• Matched to battery foil-stack requirements: Defined aluminum-to-aluminum-foil and nickel-to-copper-foil capabilities, up to 40 foil layers, and three stated weld-point sizes provide relevant flexibility for electrode-tab applications.

• Supports process-specific setup: Time, energy, power, and depth control modes allow the operating recipe to be adjusted for different materials, foil thicknesses, layer counts, and joint-strength targets.

Contact us for a quote or a custom ultrasonic battery welding solution configured around your electrode materials, foil stack, and weld-point requirements.

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