Prismatic Aluminum Case Battery Laser Welding System

Product Overview

This integrated laser welding system performs top-cover full-seam welding and sealing-pin welding for prismatic aluminum-case batteries in one production platform. It combines controlled fixturing, laser positioning, protective gas, dust extraction, and process monitoring to support stable weld formation while protecting the aluminum enclosure and top-cover plastic components. The equipment is designed for battery thicknesses from 12 to 60 mm, widths from 80 to 170 mm, and heights from 90 to 190 mm.

The system is intended for lithium battery manufacturing operations that require controlled top-cover assembly and sealing-pin joining. It supports manual cell loading and unloading, while integrating pre-welding and full welding sequences to provide a practical process solution for prototype, pilot, and production battery lines. Dedicated fixture changeover supports compatible battery formats without compromising locating accuracy.

Built around repeatable mechanical positioning, monitored laser operation, and protected welding conditions, this unit addresses the process controls needed for demanding aluminum-case battery work. Pressure monitoring, gas-flow monitoring, focal-distance monitoring, exhaust monitoring, and protective covers help maintain operational consistency and reduce the risk of weld-related defects.

Key Features

• Integrated Dual Welding Process: This system combines top-cover full-seam welding and sealing-pin welding within one machine. Manufacturers can use a common platform for two critical battery closure processes while retaining dedicated fixture and welding requirements for each operation.

• High-Precision Top-Cover Fixturing: A traveling fixture clamps the battery for vertical welding with the top-cover surface used as the datum. Repeated fixture positioning tolerance is ±0.02 mm, and the gap between the master and clamping plate after clamping is limited to ≤0.04 mm.

• Controlled Full-Seam Laser Welding: The top-cover process uses pre-welding with a pressing function and 6 to 8 weld points before full welding. Laser-head X/Y/Z repeated positioning tolerance is ±0.02 mm, trajectory deviation is ±0.05 mm, and welding speed is ≥70 mm/s.

• Ring-Spot Laser Configuration: The full-seam welding station uses a 2 kW + 1 kW ring-spot laser configuration with line diameter >100 um/600 um and a water chiller. Laser welding-head and transmission-fiber power fluctuation is limited to ≤3%, with power linearity ≥0.99.

• Vision-Guided Sealing-Pin Welding: A CCD system captures sealing-pin position with capture-positioning accuracy of ≤±0.03 mm. Automatic focal-distance detection has a resolution of ≤0.02 mm, supporting accurate welding alignment before the pre-weld and full-weld sequence.

• Adjustable Protective Gas Delivery: Coaxial N2 shielding gas with purity ≥99.99% helps prevent welding oxidation during top-cover welding. Gas flow is adjustable with 0.1 L/min resolution, with flow monitoring and alarms; flow, angle, and distance of the welding protection-gas device are adjustable and traceable.

• Real-Time Focus and Height Control: Laser-head height is adjustable and visualized at 0.05 mm resolution. Automatic defocus measurement provides abnormal-condition alarms with resolution ≤0.05 mm, while the sealing-pin process monitors focal distance in real time and compensates the welding Z axis.

• Clean Welding Environment: Integrated dust extraction removes welding smoke and spatter. Stainless-steel main ducting, adjustable airflow valves, monitored duct pressure, and stop alarms for excessive or insufficient pressure support disciplined environmental control at the welding stations.

• Battery Surface Protection: Non-metal materials are used at battery-contact locations for top-cover welding fixtures. Closely fitted protective covers prevent welding spatter from contaminating battery surfaces and help protect plastic sections around the top-cover terminals from heat exposure.

• Efficient Format Changeover: Top-cover and sealing-pin welding are integrated in one machine, with fixture changes for different compatible products completed in ≤30 minutes. The changeover arrangement is designed to remain simple to disassemble and install without affecting fixture locating accuracy or equipment service life.

Applications

Technical Specifications

Why Choose This Product

• Integrated process capability: Combining top-cover full welding and sealing-pin welding in one unit reduces the equipment footprint required for these two battery closure operations while retaining process-specific positioning and protection measures.

• Measured process control: Fixture tolerances, laser travel tolerances, focus monitoring, gas-flow monitoring, air-pressure monitoring, and duct-pressure alarms provide defined controls for repeatable operation.

• Designed for aluminum-case quality: The specified laser, shielding, pre-weld, protection-cover, and extraction arrangements are directed toward clean, well-formed welds on aluminum cases and protection of sensitive terminal plastic components.

• Production-focused serviceability: Compatible-format fixture changes are specified at ≤30 minutes, supporting efficient product transitions without sacrificing fixture positioning accuracy or machine service life.

• Operational performance targets: The system is specified for ≥120PPM/10H capacity based on manual operating speed, a 99.5% equipment-caused qualification rate, and ≥95% equipment availability.

Contact us for a quote or a custom fixture and welding-process solution for your prismatic battery format.

Trusted by Industry Leaders