Battery PACK Laser Welding Machine

Battery PACK laser welding machines are high-precision, non-contact automated welding equipment specially designed for the assembly of lithium battery modules and packs (power / energy storage / consumer electronics). They are key equipment in new energy battery manufacturing, mainly used for reliable connection of cell terminals, busbars and connecting sheets.

1.Core Application Scenarios

●Terminal-to-busbar Welding: Series / parallel connection between square / cylindrical / pouch cell terminals (copper / aluminum) and aluminum / copper busbars.

●Tab Welding: Welding of thin copper / aluminum tabs to adapter sheets and current collectors (e.g., 4680 full-tab cells).

●Sealing & Structural Parts: Sealing welding of battery covers, explosion-proof valves, and welding of module end plates / brackets.

●Copper-Aluminum Dissimilar Welding: Solving the common connection challenge of copper (cathode) to aluminum (anode / busbar) in power batteries.

2.Main Equipment Types (By Structure / Laser Source)

2.1By Mechanical Structure

●Gantry Type (Platform Type)

○Application: Square battery modules, large-scale energy storage PACKs.

○Features: Large XYZ travel, high rigidity, high precision (±0.02~0.05mm).

●Galvanometer Scanning Type

○Application: Cylindrical batteries (18650 / 21700 / 4680), dense spot welding.

○Features: High speed (10~30 spots/sec), no mechanical movement, suitable for circular / array solder joints.

●Robot + Welding Head

○Application: Complex 3D trajectories, multi-variety flexible production lines.

○Features: 6-axis linkage, multi-angle welding, compatible with MES / automated lines.

2.2By Laser Type (Mainstream)

●Continuous Wave (CW) Fiber Lasers: 1070nm, 1~6kW. First choice for mass production, deep penetration welding, fast speed, high stability.

●Quasi-Continuous Wave (QCW) Fiber Lasers: Pulse + continuous mode. Suitable for thin copper / aluminum and splash-prone materials with smaller heat-affected zones.

●Green / Blue Lasers: 515 / 450nm. Dedicated for copper materials, high absorption rate (>30%), low spatter, ideal for ultra-thin copper foils.

3.Core Technologies & Configurations

●Visual Positioning (CCD): Coaxial / off-axis high-definition cameras for automatic positioning, deviation correction and incoming material compensation, with ±50μm precision.

●Beam Shaping / Swing Welding: Ring spot, spiral swing to expand molten pool, reduce copper-aluminum cracks / pores and improve forming quality.

●Real-time Monitoring (Welding Inspection): Molten pool monitoring, OCT penetration detection, closed-loop energy control, AI defect identification (pores / cold joints / spatter).

●Protection & Cooling: Argon / nitrogen protection (anti-oxidation), industrial water cooling (temperature control ±1℃), fully enclosed safety cover.

4.Key Advantages (vs. Resistance Welding / MIG)

1.Ultra-high precision: Micron-level light spot, non-contact, no stress, minimal thermal deformation.

2.Reliable strength: Large depth-to-width ratio, metallurgical bonding, low internal resistance, vibration resistance.

3.High efficiency: High-speed galvanometer / robot, 300~1000 spots/min cycle time.

4.Strong flexibility: One-key type change, compatible with multi-spec cells, supports data traceability.

5.High yield: 100% online inspection, automotive-grade zero-defect control.

5.Typical Parameters (Power Battery)

●Laser Power: 1500~3000W (mainstream)

●Positioning Accuracy: ±0.02~0.05mm

●Welding Speed: 20~100mm/s (continuous); 10~30 spots/sec (galvanometer)

●Applicable Materials: Pure copper, pure aluminum, copper-aluminum alloy, nickel, stainless steel

●Capacity: 10~60PPM (module line)

6.Selection Criteria

1.Cell Type: Galvanometer for cylindrical cells; gantry / platform for square cells; precision platform for pouch cells.

2.Materials: Copper-dominated → Green / Blue laser; copper-aluminum hybrid → QCW / swing welding with high-reflection protection.

3.Capacity: Full-automatic lines for mass production; semi-automatic / workbenches for small batches.

4.Quality Requirements: Automotive-grade applications must be equipped with OCT penetration + AI vision + data traceability.

5.Machine Technical Parameters: