Battery Top Cap Welding Equipment

1. Equipment Overview

Equipment Name: Battery Top Cap Welding Equipment

Model: HY-TCW9090

Application: Precise welding of top caps onto battery cases, ensuring airtight sealing and electrical connectivity for prismatic and pouch batteries.

2. Mechanical Specifications

Equipment Dimensions:

Length: 1800 mm

Width: 1400 mm

Height: 1900 mm

Weight: 1300 kg ± 5%

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

Worktable Material: Anodized aluminum with anti-static and wear-resistant surface.

Motion System: Precision servo-driven X-Y-Z axes with linear guide rails.

3. Welding Specifications

Welding Technology:

Laser Welding (standard).

Optional: Resistance or Ultrasonic Welding.

Laser Type: Fiber laser, 1064 nm wavelength.

Laser Power: 500–3000 W (adjustable).

Welding Speed: Up to 10 welds per minute (process-dependent).

 Welding Spot Size: 0.1–0.5 mm (configurable).

Welding Accuracy: ±0.03 mm.

Material Compatibility:

Top Cap Materials: Aluminum, nickel, and copper.

Battery Case Materials: Aluminum and stainless steel.

4. Vision and Alignment System

Alignment Accuracy: ±0.02 mm.

Camera Specifications:

Resolution: 5 MP industrial-grade CCD camera.

Field of View: Adjustable for varying cap sizes.

Lighting System: Adjustable LED illumination for enhanced visibility.

Inspection Features:

Pre-weld alignment and cap placement verification.

Post-weld inspection for seam integrity and defects.

5. Control and Interface

Control System: PLC with integrated HMI for process control.

Interface:

10-inch capacitive touchscreen with user-friendly GUI.

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

Programmable Parameters:

Laser power, duration, and focus.

Welding patterns and sequences.

Recipe storage for various battery models.

Data Logging:

Internal Capacity: 1 TB SSD for process history.

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: 10 kW.

Control Voltage: 24V DC for auxiliary systems.

7. Safety Features

Emergency Stop: Emergency stop buttons on all accessible panels.

Overload Protection: Real-time monitoring of force and welding power.

Laser Safety: Fully enclosed Class 1 laser operation with interlock systems.

Protective Barriers: Transparent enclosure with safety interlocks for operator protection.

Error Detection: Audible and visual alarms for misalignment, overheating, or defective welds.

8. Environment & Installation

Operating Environment:

Temperature: 10–30°C

Humidity: ≤65% RH (non-condensing).

Noise Level: ≤75 dB during operation.

Installation Requirements:

Flat, vibration-free surface.

Minimum clearance: 800 mm on all sides.

9. Cooling System

Type: Water-cooled laser module with independent chiller.

Flow Rate: 10–15 L/min.

Cooling Power: 3.5 kW.

10. Maintenance and Warranty

Maintenance Schedule:

Weekly: Clean laser lens, inspect fixtures, and check alignment.

Monthly: Inspect servo motors, cooling systems, and electrical connections.

Quarterly: Calibrate alignment and welding systems.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.