Battery Case Insertion and Top Cap Pre-Welding Equipment

1.Battery Case Insertion and Top Cap Pre-Welding Equipment Overview

Equipment Name: Battery Case Insertion and Top Cap Pre-Welding Equipment

Model: HY-CIW8080

Application: Automated insertion of battery cells into protective cases and precise pre-welding of top caps to ensure structural integrity before final welding. Suitable for prismatic and pouch batteries.

2. Mechanical Specifications

Equipment Dimensions:

Length: 2000 mm

Width: 1500 mm

Height: 1900 mm

Weight: 1500 kg ± 5%

Frame Material: Reinforced steel frame with powder coating for durability.

Worktable Material: Anodized aluminum alloy with anti-static surface.

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

3. Case Insertion Specifications

Insertion Accuracy: ±0.1 mm.

Cell Compatibility:

Width: 50–100 mm.

Height: 50–200 mm.

Thickness: 5–20 mm.

Insertion Speed: Up to 10 cases per minute (process-dependent).

Grip Mechanism: Pneumatic or servo-controlled gripper with adjustable force for different cell materials.

Case Materials: Aluminum, stainless steel, and polymer.

4. Top Cap Pre-Welding Specifications

Welding Technology:

Laser Welding (standard).

Optional: Ultrasonic or Resistance Welding.

Laser Power: 500–2000 W (adjustable).

Welding Spot Size: 0.2–0.5 mm (programmable).

Pre-Welding Accuracy: ±0.05 mm.

Cap Material Compatibility: Aluminum, nickel, and copper.

Pre-Welding Speed: Up to 8 welds per minute.

5. Vision and Alignment System

Alignment Accuracy: ±0.03 mm.

Camera:

Type: Industrial-grade CCD camera.

Resolution: 5 MP with real-time defect detection.

Lighting: Adjustable LED for enhanced visibility of cases and caps.

Inspection Features:

Pre-insertion cell alignment.

Post-welding inspection for proper cap positioning and weld integrity.

6. Control and Interface

Control System: PLC with integrated HMI for seamless operation.

Interface:

12-inch touchscreen with intuitive UI.

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

Programmable Parameters:

Case insertion speed and force.

Welding power, duration, and spot size.

Recipe storage for various battery types and sizes.

Data Logging:

Internal Capacity: 1 TB for process records.

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: 8 kW.

Control Voltage: 24V DC for auxiliary systems.

8. Safety Features

Emergency Stop: Strategically placed buttons on the front and rear panels.

Overload Protection: Real-time monitoring of force during case insertion and cap welding.

Laser Safety: Class 1 laser safety enclosure with interlock system.

Protective Enclosure: Transparent cover with interlocks to prevent operation during maintenance.

Error Alarms: Audible and visual alarms for misalignment, insertion failure, or welding defects.

9. Environment & Installation

Operating Environment:

Temperature: 10–35°C

Humidity: ≤60% RH (non-condensing).

Noise Level: ≤75 dB during operation.

Installation Requirements:

Flat, vibration-free surface.

Minimum clearance: 800 mm on all sides.

10. Cooling System

Type: Water-cooled laser module with independent chiller.

Flow Rate: 10–15 L/min.

Cooling Power: 3.5 kW.

11. Maintenance and Warranty

Maintenance Schedule:

Weekly: Clean insertion gripper, laser lens, and alignment components.

Monthly: Inspect servo motors, pneumatic system, and cooling system.

Quarterly: Full calibration of alignment and welding systems.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.