Intelligent 8000W Ultrasonic Battery Welding Machine for Up to 120 Layer Electrode Welding

Product Overview

This intelligent ultrasonic battery welding system is designed for high-power metal-to-metal joining in battery electrode and tab fabrication. Its 8,000 W ultrasonic output, full-bridge regulated circuit, automatic frequency tracking, and constant-amplitude operation support repeatable welding without manual frequency adjustment. Multiple control modes for time, energy, power, and depth give process engineers practical control over the weld cycle.

The equipment is intended for welding aluminum strip to multilayer aluminum foil and nickel strip to multilayer copper foil. It is suited to battery cell manufacturing, pilot production, electrode development, and laboratory process validation where dense foil stacks and dependable electrical connections must be joined efficiently. Supported weld-point sizes of 3 x 10 mm, 3 x 20 mm, and 3 x 30 mm accommodate common tab and current-collector welding tasks.

Built for demanding repetitive operation, this unit combines a wear-resistant powder-alloy welding head, a high-rigidity lower ultrasonic electrode, real-time process display, and automatic compensation functions. These features help maintain stable output frequency, strong weld formation, low internal resistance, and consistent weld quality across production runs.

Key Features

• 8,000 W Full-Bridge Ultrasonic Drive: An optimized international full-bridge regulated circuit provides constant-amplitude output and automatic frequency tracking. The system avoids manual frequency adjustment while maintaining a stable ultrasonic welding condition.

• Multi-Mode Intelligent Process Control: CPU control supports time, energy, power, energy, and depth operating modes. This gives users a practical basis for developing and managing welding settings for different foil counts, strip materials, and thickness combinations.

• Automatic Amplitude Compensation: The equipment automatically adjusts amplitude output during operation. By stabilizing ultrasonic amplitude, the system improves welding consistency and supports more uniform joint quality from cycle to cycle.

• High-Durability Powder-Alloy Welding Head: The welding head uses imported powder-alloy steel with high hardness. Its pattern is finished by high-precision grinding, and the specified service life exceeds 150,000 operations on one side.

• Rigid Wear-Resistant Lower Electrode: The lower ultrasonic electrode is made from carefully selected imported special mold steel. Its wear resistance, high-temperature resistance, toughness, mechanical rigidity, and low deformation after heat treatment support consistent output-frequency performance and strong, stable high-frequency displacement amplitude.

• Clean, Reliable Weld Formation: Properly configured welds are designed to be firm and low in internal resistance, with no false welding, powder vibration, separator burning, insulating-tape heating, electrode-tab cracking, or foil cracking. Remaining welded contact area between metals is specified at more than 80%.

• Controlled Surface Quality: The welding result is characterized by a smooth surface without wrinkles, no raised burrs on the reverse side, and full, clear weld spots. Joint-position integrity and destructive tensile strength can be evaluated according to layer count and material thickness.

• 4.3-Inch Bilingual Touchscreen: 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 while viewing real-time frequency and welding power.

• Startup Self-Inspection and Fault Alarms: On startup, the unit scans welding-system parameters and displays them in real time. When a fault is identified, it issues an alarm, helping prevent operation while the system is in an abnormal condition.

• Weld-Quality Data Monitoring: Upper and lower limits can be set from real-time welding-data parameters to monitor every welded product. When a value exceeds the defined range, the equipment provides an alarm indication for prompt process review.

Applications

Technical Specifications

Why Choose This Product

• Engineered for multilayer electrode work: The stated ability to weld up to 120 layers of aluminum foil or copper foil addresses demanding battery tab-joining requirements with defined strip and weld-point configurations.

• Built around output consistency: Constant-amplitude operation, automatic frequency tracking, and automatic amplitude compensation are focused on stable ultrasonic output and repeatable welding performance.

• Designed for service life under repeated use: The high-hardness, powder-alloy welding head is precision ground and specified for more than 150,000 operations per side, while the lower electrode is selected for wear resistance and mechanical rigidity.

• Supports controlled welding decisions: Real-time frequency and welding-power display, configurable parameter limits, self-inspection, and alarms provide process teams with direct information for monitoring welding conditions.

• Protects joint quality and downstream assembly: The stated welding outcome emphasizes low resistance, strong weld formation, clean surfaces, no reverse-side raised burrs, and avoidance of damage such as separator burning or foil cracking.

Contact us for a quote or a custom solution matched to your electrode materials, foil-layer count, strip dimensions, and required weld-point size.

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