Intelligent Ultrasonic Battery Welding Machine for 60 Layer Electrode Welding

Product Overview

This intelligent ultrasonic battery welding machine is engineered for dependable electrode-tab bonding in battery cell manufacturing and research. Its 3600W, 24 kHz ultrasonic platform combines full-bridge regulated circuitry, constant-amplitude output, and automatic frequency tracking to maintain a strong, stable welding action without manual frequency adjustment. CPU-based control supports time, energy, power, and depth-oriented operating modes, giving users a practical process-control foundation for demanding metal-to-metal welds.

The equipment is designed for welding aluminum strip to multilayer aluminum foil and nickel strip to multilayer copper foil, supporting electrode stacks of up to 60 layers. It is suited to battery R&D laboratories, pilot lines, and manufacturing operations that require repeatable tab-to-electrode joining. Adjustable weld parameters, real-time operating visibility, and bilingual touchscreen operation help technicians establish and monitor welding conditions efficiently.

Built around wear-resistant ultrasonic tooling and a rigid lower sonotrode assembly, this unit is intended for consistent output under repeated duty. Startup self-diagnostics, fault alarms, automatic amplitude compensation, and weld-quality data limits help identify abnormal conditions before they affect production. The resulting welds are designed to be firm, low in internal resistance, flat in appearance, and reliable across material and stack configurations within the stated capability.

Key Features

• 3600W 24 kHz Ultrasonic Platform: The system delivers 3600W of ultrasonic power at 24 kHz for robust metal-to-metal electrode welding. Full-bridge regulated circuitry is optimized for constant-amplitude output and automatic frequency tracking, avoiding the need for manual frequency adjustment during normal operation.

• Intelligent CPU Process Control: CPU control supports time, energy, power, and depth modes to suit different process requirements. This flexibility allows users to select a control approach that aligns with electrode material, tab material, foil stack thickness, and required weld condition.

• Automatic Amplitude Compensation: The equipment automatically adjusts amplitude output to improve amplitude stability. By compensating output automatically, the unit supports more consistent welding performance and helps maintain weld-quality consistency across repeated cycles.

• Up to 60-Layer Electrode Welding: The stated welding capability covers 0.2 mm aluminum strip with up to 60 layers of aluminum foil and 0.2 mm nickel strip with up to 60 layers of copper foil. Supported weld spot formats are 3 x 6 mm, 3 x 8 mm, and 3 x 12 mm for both listed applications.

• Precision Powder-Alloy Welding Head: The welding head is made from imported powder-alloy steel with high hardness. Its pattern is produced by high-precision grinding, providing a durable working surface and a stated service life exceeding 150,000 cycles on one side.

• Rigid Wear- and Heat-Resistant Lower Sonotrode: The lower ultrasonic electrode uses carefully selected imported special mold steel. Its wear resistance, high-temperature resistance, toughness, mechanical rigidity, and low heat-treatment deformation support high frequency consistency and strong, stable high-frequency displacement amplitude.

• 4.3-Inch Bilingual Touchscreen Interface: A 4.3-inch anti-interference touch display provides Chinese and English operation. Users can set trigger time, welding time, power, and secondary-wave delay time, while real-time frequency and welding power are displayed for process observation.

• Startup Self-Diagnostics and Fault Alarms: At startup, the welding system scans parameters and displays them in real time. When a fault is detected, the unit issues an alarm prompt, helping prevent operation under fault conditions and supporting disciplined equipment readiness checks.

• Weld-Quality Data Monitoring: Real-time welding data can be used to define upper and lower parameter limits for each welded product. When operating values fall outside the configured limits, the equipment provides an alarm prompt to support product-level quality monitoring.

• Clean, Reliable Weld Results: The welding process is designed to produce firm joints with low internal resistance. The stated results include no false welding, powder vibration, separator burning, insulation-tape heating, or cracking of tabs and electrode sheets; residual metal-to-metal weld area exceeds 80%.

Applications

Technical Specifications

Why Choose This Product

• Process stability built into the control architecture: Constant-amplitude output, automatic frequency tracking, and automatic amplitude compensation are designed to keep ultrasonic output stable and reduce reliance on manual adjustment during welding operations.

• Tooling selected for sustained duty: The powder-alloy welding head and imported special mold-steel lower electrode prioritize hardness, wear resistance, heat resistance, rigidity, and dimensional stability after heat treatment. These material choices support long-term consistency in a high-frequency welding environment.

• Quality monitoring at the equipment level: Startup self-testing, real-time frequency and welding-power display, fault alarms, and configurable data limits give operators visible process feedback. This supports a controlled response when conditions deviate from established welding windows.

• Capability matched to multilayer battery electrodes: Defined welding configurations for aluminum/aluminum-foil and nickel/copper-foil assemblies up to 60 layers provide a clear basis for evaluating suitability for electrode-tab production requirements.

• Operator-focused configuration and verification: The bilingual touchscreen combines accessible setup with adjustable timing, power, and secondary-wave delay settings. Real-time information and stated weld-quality outcomes support repeatable setup, inspection, and process development work.

Contact us for a quote or to discuss a battery electrode welding solution configured around your material stack, tab dimensions, weld spot requirement, and process-control needs.

Trusted by Industry Leaders