Dual-Station Terminal Pole Welding Machine

1.  Dual-Station Terminal Pole Welding MachineOverview

Equipment Name: Dual-Station Terminal Pole Welding Machine

Model: HY-DTPW2024

Application: High-speed and precise welding of terminal poles for prismatic, cylindrical, and pouch battery cells. The dual-station design ensures continuous operation, improving efficiency and reducing downtime.

2. Mechanical Specifications

Equipment Dimensions:

Length: 2500 mm

Width: 1800 mm

Height: 2100 mm

Weight: 1800 kg ± 5%

Frame Material: Reinforced steel with anti-vibration structure.

Worktable Material: Hard-coated aluminum with anti-static surface.

Motion System:

Dual servo-controlled X-Y-Z axes for each station.

Precision linear guide rails for stable operation.

3. Welding Specifications

Welding Technology:

Standard: Laser Welding.

Optional: Ultrasonic Welding or Resistance Welding.

Laser Specifications:

Wavelength: 1064 nm.

Power: 200 W–500 W (adjustable).

Welding Speed: Up to 15 welds per minute per station.

Welding Accuracy: ±0.02 mm.

Terminal Pole Material Compatibility: Copper, aluminum, and nickel.

Battery Compatibility:

Length: 50–200 mm

Width: 30–150 mm

Height: 5–50 mm

4. Dual-Station Features

Station Operation:

Simultaneous or independent operation for different battery models.

Automatic switching for seamless production.

Cycle Time: ≤10 seconds per weld (per station).

Automatic Loading/Unloading: Pneumatic grippers or robotic arm integration.

5. Vision and Alignment System

Alignment Accuracy: ±0.02 mm.

Camera Specifications:

High-resolution CCD cameras for terminal and pole alignment.

Resolution: 5 MP.

Lighting System: Adjustable LED ring lights for optimal visibility.

Inspection Features:

Pre-weld alignment verification.

Post-weld inspection for structural integrity and weld quality.

6. Control and Interface

Control System: Advanced PLC-based control with independent modules for each station.

HMI:

12-inch capacitive touchscreen with intuitive user interface.

Multi-language support (English, Chinese, others).

Programmable Parameters:

Laser power, duration, and spot size.

Station-specific recipes for different terminal designs.

Data Logging:

Internal Storage: 1 TB SSD for process data.

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

7. Electrical Specifications

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

Maximum Power Consumption: 10 kW.

Control Voltage: 24V DC for auxiliary systems.

8. Safety Features

Emergency Stop: Accessible at both stations and central control panel.

Laser Safety: Class 1 laser enclosures with safety interlocks.

Overload Protection: Real-time monitoring of welding current and laser system.

Protective Barriers: Transparent polycarbonate enclosures with interlocks.

Defect Alarms: Audible and visual alerts for misaligned terminals or welding defects.

9. Environmental and Installation Requirements

Operating Environment:

Temperature: 15–30°C

Humidity: ≤60% RH (non-condensing).

Noise Level: ≤70 dB during operation.

Installation Requirements:

Flat, vibration-free surface.

Minimum clearance: 1,000 mm on all sides.

10. Cooling System

Type: Integrated water cooling system for laser and welding components.

Cooling Capacity: 5 kW.

Water Flow Rate: 10–15 L/min.

Optional: Air-cooled system for lower-power operations.

11. Maintenance and Warranty

Maintenance Schedule:

Weekly: Clean lenses, inspect alignment systems, and check cooling units.

Monthly: Calibrate laser power and inspect terminal grippers.

Quarterly: Perform full diagnostic of electrical and mechanical components.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.