Battery Terminal Tab Welding Equipment

1. Battery Terminal Tab Welding Equipment Overview

Equipment Name: Battery Terminal Tab Welding Equipment

Model: HY-TTW4040

Application: High-precision welding of battery terminal tabs for prismatic, pouch, and cylindrical batteries. Designed for a variety of tab materials including aluminum, nickel, and copper.

2. Mechanical Specifications

Equipment Dimensions:

Length: 1600 mm

Width: 1200 mm

Height: 1800 mm

Weight: 1300 kg ± 5%

Frame Material: High-strength steel frame with powder coating for durability.

Worktable: Hardened stainless steel with anti-static surface treatment.

Motion System: Servo motor-driven X-Y-Z axes with linear guide rails for high precision.

3. Welding Specifications

Welding Technology:

Standard: Ultrasonic welding.

Optional: Laser or resistance welding.

Welding Power: Adjustable, 2–10 kW depending on tab thickness and material.

Welding Speed: 5–10 welds per minute (process-dependent).

Welding Accuracy: ±0.1 mm.

Tab Thickness Range: 0.1–0.5 mm.

Tab Material Compatibility: Aluminum, copper, nickel, and multi-layer laminates.

4. Vision and Positioning System

Camera Specifications:

Type: High-resolution CCD camera with auto-focus capability.

Resolution: 5 MP.

Alignment Accuracy: ±0.05 mm using image recognition algorithms.

Lighting: Adjustable LED ring light for consistent illumination.

Detection Features:

Pre-weld alignment verification.

Post-weld inspection for defects such as cracks or misalignment.

5. Control and Interface

Control System: PLC-based control with integrated HMI (Human-Machine Interface).

Display: 12-inch touchscreen with intuitive UI.

Programmable Features:

Welding parameters (power, duration, pressure).

Alignment and positioning adjustments.

Recipe storage for different battery types.

Data Logging:

Internal storage: 1 TB SSD.

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

6. Electrical Specifications

Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.

Maximum Power Consumption: 8 kW.

Control Voltage: 24V DC for internal systems.

7. Safety Features

Emergency Stop: Multiple emergency stop buttons strategically placed.

Overload Protection: Real-time current and force monitoring with automatic system shutdown.

Temperature Protection: Sensors to prevent overheating of welding components.

Safety Enclosure: Transparent safety covers with interlocks to prevent operation when open.

8. Environment & Installation

Operating Environment:

Temperature: 10–30°C

Humidity: ≤60% RH (non-condensing).

Noise Level: ≤75 dB during operation.

Installation Requirements:

Flat surface with anti-vibration foundation.

Clearance: Minimum 800 mm on all sides.

9. Optional Configurations

Dual Welding Heads: For simultaneous processing of multiple tabs.

IoT Connectivity: Real-time process monitoring and predictive maintenance.

Automated Tab Feeding System: For continuous operation and improved efficiency.

10. Maintenance and Warranty

Maintenance Schedule:

Weekly: Clean welding head and lens.

Monthly: Inspect and calibrate alignment systems.

Quarterly: Lubricate moving parts and check electrical connections.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months upon request.