Ultrasonic Metal Welding Machine Battery Cap Aluminum Strip Single Spot Welding

Product Overview

This ultrasonic metal welding system is engineered for single-point joining of battery caps and aluminum tabs or strips. It converts high-power ultrasonic electrical oscillation into mechanical energy through the transducer, applying vibration at the metal interface to generate instantaneous heat and promote molecular interpenetration between the joined materials. The result is a solid, clearly defined weld point without relying on conventional fusion welding.

The equipment is suited to battery cap assembly operations requiring a 3 mm x 3 mm single weld point on aluminum tab material. Its 40 kHz ultrasonic platform, 800 W output capability, pneumatic actuation, and adjustable process settings support controlled production of battery components. It is relevant to battery manufacturing, laboratory battery development, advanced materials joining, and process verification work where a compact, repeatable metal-bonding operation is needed.

Built around an ultrasonic generator, transducer, tooling, pneumatic components, and a rigid workbench arrangement, this unit is designed for demanding repeated use. Digital control, automatic frequency tracking, constant-amplitude functionality, and upper and lower quality alarm limits help operators maintain defined welding conditions and identify process deviations promptly.

Key Features

• 40 kHz Ultrasonic Joining Platform: The system operates at 40 kHz and uses a transducer to convert high-power ultrasonic signals into mechanical energy at the metal interface. This controlled vibration-based process supports rapid joining of aluminum tab and battery-cap materials.

• 800 W Output Capability: The transducer is rated for output power of at least 800 W, while the specified ultrasonic power is 800 W. This provides the power capacity required for the stated single-point aluminum tab welding application.

• Intelligent Digital Control: An advanced CPU-based digital circuit supports energy, power, and time control modes. Operators can select the control approach that best matches their material and process requirements.

• Automatic Frequency Tracking: The generator automatically tracks ultrasonic frequency during operation. This function supports stable operation as working conditions change and helps keep the system aligned with its designed ultrasonic operating condition.

• Constant-Amplitude Function: A switching power supply provides constant-voltage and constant-current operation for constant amplitude. Amplitude is continuously adjustable, with a half-cycle adjustment range of 3 to 10 um.

• Adjustable Welding Pressure and Time: Welding pressure is adjustable from 0 MPa to 1 MPa, and time control is adjustable from 0 to 60 S. These settings give process teams defined adjustment capability for material qualification and routine production setup.

• Quality Limit Alarms: Energy, time, and power each include upper- and lower-limit quality alarms. The alarm functions provide a direct means to monitor whether a welding cycle remains within the selected process window.

• Durable High-Speed-Steel Tooling: The welding head is made from imported high-speed steel and has a service life of at least 120,000 cycles. Two usable welding faces extend the practical serviceability of the tool for repeated single-point operations.

• Defined Weld Geometry: The specified weld point is a single 3 mm x 3 mm point, with 3 mm weld-point length and 3 mm width. Available mesh or straight-line surface patterns and a 0.08 mm weld-point height support a defined tooling interface.

• High Finished-Product Standard: The specified product requirement calls for firm welds with full, clear weld points and no false welding, burn-through, or missed connections. Under qualified material conditions, the stated product pass rate is at least 99.8%, and weld tensile strength is at least 25 N.

Applications

Technical Specifications

Why Choose This Product

• Process-Controlled Ultrasonic Architecture: The combination of CPU-based digital control, selectable energy, power, and time modes, and automatic frequency tracking provides a technically focused platform for controlled metal joining.

• Built for Repeat-Cycle Service: Imported high-speed-steel tooling, at least 120,000-cycle welding-head life, and two usable welding faces support sustained operation and practical maintenance planning.

• Defined Quality Criteria: Clear requirements for weld appearance, at least 25 N tensile strength, and a stated pass rate of at least 99.8% under qualified material conditions give procurement and process teams concrete performance references.

• Adjustment for Material and Process Needs: Continuously adjustable amplitude, 0 MPa to 1 MPa adjustable pressure, and 0 to 60 S adjustable time control enable the equipment to be set around actual material conditions.

• Production-Oriented Monitoring: Upper- and lower-limit alarms for energy, time, and power help support operational consistency by making deviations from selected limits visible during welding.

Contact us for a quote or a custom solution aligned with your battery cap, aluminum tab, tooling, and process-control requirements.

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