Smart 4500W Ultrasonic Battery Tab Welding Machine for 70 Layer Electrode Stacks

Product Overview

This intelligent ultrasonic welding system is engineered for high-strength battery tab and electrode-stack joining where joint consistency, low resistance, and process control are essential. Its 4500 W ultrasonic output, 24 kHz operating frequency, CPU control, and constant-amplitude full-bridge circuit are designed to deliver stable energy during demanding production work. Automatic frequency tracking removes the need for manual adjustment and helps maintain repeatable welding output as operating conditions change.

The equipment is suited to battery cell fabrication tasks involving aluminum strip to aluminum foil and nickel strip to copper foil. It supports material stacks of up to 70 foil layers, making it relevant to laboratory development, pilot-line work, and controlled electrode-tab processing. Configurable time, energy, power, and depth-based operating modes allow process teams to select a welding approach appropriate to the joint and material construction.

Built around hard-wearing tooling and monitored operating parameters, this unit is intended for reliable repeated use. The powder-alloy welding horn, imported special mold-steel lower electrode, controlled high-frequency displacement amplitude, and automatic amplitude compensation work together to support strong, clean welds while protecting sensitive battery materials from avoidable process damage.

Key Features

• Constant-Amplitude Full-Bridge Output: The optimized full-bridge regulated circuit provides constant-amplitude ultrasonic output. Automatic frequency tracking maintains operation without manual frequency adjustment, supporting stable performance through repeated weld cycles.

• Intelligent Multi-Mode Control: CPU control supports time, energy, power, and depth modes for flexible process setup. This gives operators practical control over the parameters that govern weld formation across different tab, foil, thickness, and layer-count combinations.

• 4500 W 24 kHz Welding Platform: Rated 4500 W output at 24 kHz provides the ultrasonic energy required for battery tab welding applications. The controlled high-frequency motion is designed to produce a strong and stable welding action at the joint interface.

• Long-Life Powder-Alloy Welding Horn: The welding horn uses imported powder-alloy steel with high hardness and precision-ground patterning. Its specified service life exceeds 150,000 operations on one side, helping reduce tooling interruption in repeated welding work.

• Wear-Resistant Lower Electrode: The ultrasonic lower electrode is manufactured from selected imported special mold steel. Wear resistance, high-temperature resistance, toughness, mechanical rigidity, and low distortion after heat treatment support consistent ultrasonic output frequency and robust high-frequency displacement amplitude.

• Clean Battery-Tab Weld Quality: The welding process is designed to form firm joints with low internal resistance while avoiding false welding, powder vibration, separator burning, insulation-tape heating, and tab or electrode-sheet cracking. Residual welded interface area between metals is greater than 80%.

• Controlled Surface Finish: Completed joints are designed to remain flat and free from wrinkles, with no raised burr on the reverse side. Clear, full weld points and non-cracked weld locations help users assess joint integrity before downstream cell assembly steps.

• 7-Inch Bilingual Touchscreen: A 7-inch interference-resistant touch display provides Chinese and English user interfaces. Operators can set trigger time, welding time, power, and secondary-wave delay while viewing real-time frequency and welding power.

• Start-Up Self-Diagnostics and Alarms: On power-up, the system scans welding-system parameters and displays them in real time. Fault conditions generate an alarm, helping prevent operation when the equipment identifies an abnormal system condition.

• Weld-Data Quality Assistance: Upper and lower limits can be set from real-time welding data to monitor individual products. When a weld parameter falls outside the configured band, the equipment issues an alarm for timely quality review.

• Automatic Amplitude Compensation: The unit automatically adjusts amplitude output to keep the amplitude more stable. This compensation supports welding stability and helps maintain consistent welding quality during operation.

Applications

Technical Specifications

Why Choose This Product

• Purpose-Built Battery Stack Capability: The specified aluminum-to-aluminum and nickel-to-copper welding capabilities address foil stacks of up to 70 layers, with defined weld-point dimensions for controlled battery-tab joining.

• Process Stability by Design: Constant-amplitude output, automatic frequency tracking, and automatic amplitude compensation are integrated to stabilize the ultrasonic welding process and support consistent results over repeated operation.

• Tooling for Repeated Duty: The high-hardness, precision-ground powder-alloy welding horn and special mold-steel lower electrode are selected for durability, rigidity, wear resistance, and stable high-frequency performance.

• Quality Visibility at the Machine: Real-time frequency and welding-power display, start-up self-testing, fault alarms, and configurable data limits give operators direct information for monitoring welding conditions and product quality.

• Protection of Sensitive Materials: The specified welding result focuses on low-resistance, firm joints without false welding, powder vibration, separator burning, insulation-tape heating, or cracking at the tab and electrode sheet.

Contact us for a quote or a custom solution matched to your battery tab material, foil-layer count, and required weld-point size.

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