Intelligent 3000W Ultrasonic Battery Welding Machine for Up to 50 Layer Electrode Welding

Product Overview

This intelligent ultrasonic battery welding system is engineered for high-consistency joining of electrode tabs and foil stacks in battery manufacturing and laboratory production. A 3000W ultrasonic power platform, 24KHZ operating frequency, full-bridge regulated circuit, and automatic frequency tracking work together to maintain stable amplitude output without manual adjustment. CPU control supports time, energy, power, and depth-oriented welding modes, giving operators a practical basis for matching the welding process to tab material, foil stack, and joint requirement.

The equipment is intended for welding 0.1mm aluminum strip to up to 50 layers of aluminum foil, as well as 0.1mm nickel strip to up to 50 layers of copper foil. Specified weld spot formats include 33mm, 34mm, and 3*8mm. It supports battery electrode manufacturing tasks where reliable metal-to-metal bonding, low internal resistance, and controlled joint appearance are important to cell assembly quality.

Built for demanding repeated operation, this unit combines a powder-alloy welding head, a selected special mold-steel lower sonotrode, and imported core components. Start-up self-diagnosis, real-time process display, fault alarms, welding-data monitoring, and automatic amplitude compensation help maintain process stability while giving operators direct visibility into each welding cycle.

Key Features

• 3000W Ultrasonic Welding Output: The system provides 3000W of welding power at 24KHZ for electrode tab and foil-stack joining. Its optimized full-bridge regulated circuit is designed for constant-amplitude output and automatically tracks frequency, avoiding the need for manual frequency adjustment during use.

• Intelligent Multi-Mode CPU Control: CPU-based control provides time, energy, power, and depth modes to support different welding conditions. This flexibility allows the welding process to be adjusted around material combinations, stack thicknesses, and the required joint result rather than relying on one fixed operating approach.

• Up to 50-Layer Electrode Capability: The equipment is specified for 0.1mm aluminum strip plus up to 50 layers of aluminum foil and for 0.1mm nickel strip plus up to 50 layers of copper foil. Supported spot sizes of 33mm, 34mm, and 3*8mm address common compact electrode connection geometries.

• Precision-Ground Powder-Alloy Welding Head: The welding head is made from imported powder-alloy steel with high hardness and a high-precision ground pattern. Its stated single-side service life exceeds 150,000 cycles, supporting long-duration production use and reducing interruptions associated with frequent tooling replacement.

• Robust Lower Sonotrode Construction: The ultrasonic lower sonotrode uses selected imported special mold steel for wear resistance, high-temperature resistance, toughness, and mechanical rigidity. Controlled heat treatment minimizes deformation, helping maintain ultrasonic output-frequency consistency and strong, stable mechanical high-frequency displacement amplitude.

• Controlled Weld Quality: The stated welding result is firm with low internal resistance. The process is designed to avoid false welding, powder vibration, separator burning, insulation-tape heating, and cracking caused by vibration in tabs or electrode sheets; residual metal-to-metal weld area is stated as more than 80%.

• Clean Joint Appearance: Properly welded parts are described as having a flat surface without wrinkles, no raised burrs on the reverse side, and full, clear welding spots. The joint location is intended to remain unbroken, while destructive tensile force can be evaluated according to layer count and material thickness.

• 4.3-Inch Bilingual Touchscreen: A 4.3-inch anti-interference touchscreen provides Chinese and English operation. Operators can set trigger time, welding time, power, and secondary-wave delay while viewing real-time frequency and welding power to confirm process behavior during operation.

• Start-Up Self-Diagnosis and Fault Alarms: The unit automatically scans welding-system parameters at start-up and displays them in real time. When a fault is detected, it issues an alarm prompt, helping prevent operation while the welding system is in a fault condition.

• Welding Data Monitoring and Amplitude Compensation: Real-time welding data can be used to define upper and lower process limits for each welded product. The equipment alarms when values fall outside those limits, while automatic amplitude compensation adjusts amplitude output to improve stability and support consistent welding quality.

Applications

Technical Specifications

Why Choose This Product

• Process Stability Built Into the Control Architecture: Constant-amplitude output, automatic frequency tracking, and automatic amplitude compensation address the operating factors that directly affect repeatable ultrasonic welding behavior.

• Durable Tooling for Repeated Production Cycles: The imported powder-alloy welding head combines high hardness with precision-ground patterning and a stated single-side life above 150,000 cycles. The lower sonotrode is selected for wear resistance, heat resistance, toughness, and rigidity.

• Visible Control of Welding Conditions: The bilingual touchscreen displays real-time frequency and welding power while allowing key timing and power settings to be adjusted. This gives production and laboratory operators an accessible interface for managing the stated welding parameters.

• Quality Monitoring That Supports Consistency: Configurable upper and lower process limits, deviation alarms, start-up self-diagnosis, and fault alarms provide practical tools for identifying abnormal operating conditions before or during welding.

• Defined Capability for Battery Electrode Materials: The specified aluminum-strip/aluminum-foil and nickel-strip/copper-foil welding capacities, together with defined spot sizes and up to 50-layer foil capability, provide a clear technical basis for selecting the equipment for electrode-tab processes.

Contact us for a quote or a custom battery welding solution matched to your electrode materials, foil-layer configuration, and required weld spot size.

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