Battery Terminal Tab Ultrasonic Welding Equipment

1. Battery Terminal Tab Ultrasonic Welding Equipment Overview

Equipment Name: Battery Terminal Tab Ultrasonic Welding Equipment

Model: HY-TTU5050

Application: Precise ultrasonic welding for battery terminal tabs, suitable for prismatic, cylindrical, and pouch cell configurations.

Key Features: High-efficiency ultrasonic welding with low heat generation, ensuring reliable bonding for battery tabs without material damage.

2. Mechanical Specifications

Equipment Dimensions:

Length: 1400 mm

Width: 1000 mm

Height: 1800 mm

Weight: 1000 kg ± 5%

Frame Material: Reinforced carbon steel with an anti-corrosion coating.

Worktable: Polished aluminum alloy with anti-static properties.

Motion System: Servo motor-controlled X-Y-Z axes with precision ball screws for positioning.

3. Ultrasonic Welding Specifications

Ultrasonic Frequency: 20 kHz ± 0.1 kHz (adjustable).

Welding Power: 1.5–5 kW (adjustable for various tab materials).

Welding Force Range: 10–200 N (adjustable).

Welding Time: 0.1–2 seconds (programmable).

Weld Area Dimensions: 2 mm × 2 mm to 20 mm × 20 mm (configurable).

Tab Thickness Range: 0.1–0.4 mm.

Material Compatibility:

Primary Materials: Aluminum, nickel, copper.

Multi-layer Combinations: Aluminum-copper, nickel-aluminum.

4. Positioning and Vision System

Alignment Accuracy: ±0.05 mm.

Camera: High-resolution CCD camera with autofocus.

Lighting System: Diffused LED lighting to enhance edge detection and surface contrast.

Error Detection: Automated detection of misalignment, surface contaminants, and defective welds.

5. Control and Interface

Control System: PLC with HMI for process control.

Interface: 10-inch touch screen with graphical user interface (GUI).

Programmable Parameters:

Welding power, frequency, and time.

Force and alignment parameters.

Custom welding recipes for different materials and sizes.

Data Storage:

Internal Capacity: 1 TB for storing weld logs.

Export Formats: CSV and JSON via USB, Ethernet, or Wi-Fi.

6. Electrical Specifications

Power Supply: AC 220V ± 10%, 50/60 Hz, single-phase.

Maximum Power Consumption: 6 kW.

Control Voltage: 24V DC for auxiliary systems.

7. Safety Features

Emergency Stop: Multiple emergency stop buttons.

Overheat Protection: Real-time monitoring of ultrasonic transducer temperature with automatic shutdown.

Force Monitoring: Built-in load cell to prevent over-pressure on tabs.

Protective Barriers: Transparent enclosure with interlocks to ensure operator safety.

8. Environment & Installation

Operating Environment:

Temperature: 10–35°C

Humidity: ≤65% RH (non-condensing).

Noise Level: ≤70 dB during operation.

Installation Requirements:

Stable, vibration-free surface.

Clearance: Minimum 600 mm on all sides.

9. Optional Configurations

Multi-Head Welding Module: For simultaneous processing of multiple tabs.

Automated Feeding System: Conveyor or robotic arm integration for continuous operation.

IoT Connectivity: Cloud-based monitoring and diagnostics.

Custom Horn Design: Tailored ultrasonic horn shapes for specific tab geometries.

10. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect and clean the ultrasonic horn and worktable.

Monthly: Calibrate alignment systems and inspect electrical connections.

Quarterly: Lubricate mechanical components and update software.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.