Equipment Overview

The ultrasonic battery welding machine is a core piece of processing equipment used in the battery assembly stage, specifically designed for metal tab and connector welding in cell manufacturing and module assembly. It uses high-frequency mechanical vibration to create solid-state bonds between metals, replacing conventional soldering and resistance welding.

Applications

On the battery production line, this machine handles three primary welding tasks:

• Tab welding: Joining the positive and negative tabs (aluminum or copper strips) extending from the cell to the current collector foils. This is the most critical electrical connection point inside the cell.

• Module series/parallel welding: Using nickel strips or aluminum connectors to join multiple cell terminals into series and parallel configurations, forming complete battery modules.

• Protection circuit board (PCB) welding: Attaching the battery pack's output tabs to the corresponding pads on the protection circuit board.

The equipment accommodates various battery formats, including pouch cells, cylindrical cells (such as 18650 and 21700), and prismatic aluminum-shell cells.

Key Features

• Low-temperature process: The welding temperature stays well below the melting point of the materials, generating no thermal impact on the internal separator or electrolyte. This builds safety directly into the manufacturing process.

• No surface preparation required: The process works directly on aluminum and copper surfaces with their natural oxide layers—no pre-cleaning or chemical treatment needed, reducing process steps.

• Consumable-free operation: No solder wire, flux, shielding gas, or other auxiliary materials are required. The process produces no spatter or fumes, keeping the internal cell environment clean.

• Consistent weld quality: Digital control over welding parameters (power, time, and pressure) ensures high repeatability from one weld to the next, with low contact resistance and excellent electrical and thermal conductivity.

• High-speed, automation-ready: Individual weld cycles typically complete in under 0.5 seconds, making the machine easy to integrate into automated production lines with robotic material handling.

System Components

The machine consists of five main components integrated into a standard cabinet: an ultrasonic generator, a transducer, a welding horn (sonotrode), an anvil (base tooling), and a pneumatic or servo-driven pressure system. The entire unit occupies approximately 1 to 2 square meters of floor space, with all welding parameters and monitoring functions controlled through a touchscreen interface.

Suitable Applications

The machine is well-suited for lap welding of various metal combinations, including aluminum-to-aluminum, copper-to-copper, and copper-to-aluminum—particularly excelling at the challenging task of joining dissimilar copper and aluminum materials. Common workpiece forms include stacked foils, sheets, busbars, and round wire terminals.

Value Proposition

For battery manufacturers, the ultrasonic battery welding machine delivers one core benefit: a reliable, high-strength, low-resistance electrical connection achieved with no thermal damage to the cell, no consumable costs, and fast cycle times. It addresses the critical joining requirements inside the cell and is a key process enabler for improving both safety and consistency in battery production. The technology has been extensively validated in high-volume production lines for both automotive power batteries and consumer electronics batteries, making it a proven, standard solution for mass manufacturing.

Key Advantages | Intelligent Error Prevention & MES Integration

1. One-Click Recipe Recall for Quick Product Changeover

The unit stores up to 500 sets of welding recipes, allowing preset of process parameters for harnesses with different cross-sections, strand counts and materials.Switching between products is simple: just recall the saved recipe, and the system automatically adjusts welding width, energy, time and pressure. No repeated manual tuning is required, ensuring consistent welding quality and faster production changeover.It also supports parameter copying, import & export, and access permission management to prevent unintended changes to critical process settings.

2. Dual Error Alarm System for Full Quality Control

Equipped with high-precision position sensors, the machine provides dual protection.

• Pre-welding alarm: It triggers an alert and locks operation if harnesses are placed reversed, skewed or mismatched, effectively preventing misplacement and wrong welding.

• Post-welding inspection alarm: The system real-time monitors welding energy, power, depth, time and frequency. Once data exceeds the preset range, the machine alarms, stops running and marks defective products.It accurately identifies insufficient welding, over-welding, low voltage, frequency deviation, overload and overheating. With a 20ms rapid response, it protects both finished products and machine components.

3. Complete Data Logging & MES Connectivity for Full Traceability

Each welding operation automatically records the recipe number, timestamp, energy, power, travel distance, pass/fail status and operator information. Tens of thousands of production records can be saved locally for data inquiry, curve playback and statistical analysis.Built-in RS232 and Ethernet ports enable seamless connection with factory MES and ERP systems. It supports remote parameter distribution, automatic data upload, full quality traceability and remote equipment monitoring, fully meeting Industry 4.0 standards and customer quality audit requirements.

4. 3000W Optimized Power for Stable Welding of Small & Medium Harnesses

Designed specifically for wire-to-wire welding and parallel splicing of harnesses from 0.5 to 20 mm², the 3000W power output is perfectly matched to the application. It avoids excessive power and overheating issues.Supported by automatic frequency tracking and amplitude compensation, the machine delivers stable welding results. It causes no wire damage or insulation burn, and produces joints with excellent tensile strength.The fully automatic workflow — wire arranging, positioning, welding and discharging — reduces manual work and human errors, and greatly improves production efficiency.

1. Working Principle

The machine converts electric energy into high-frequency mechanical vibration, and cooperates with constant pneumatic pressure to quickly remove oxide layers on the wire harness contact surfaces. It enables the clean metal surfaces to fit tightly and achieve atomic diffusion and embedding, bonding wire harnesses into a solid integrated structure. As a low-temperature solid-state welding process, it causes no metal melting or high-temperature heat diffusion, and will not damage the insulation layer of wire harnesses.

2. Core Product Advantages

1. Firm Welding and Stable Quality

Equipped with a digital closed-loop control system, the machine accurately regulates welding parameters and ensures consistent batch production results. Welded wire harnesses form an integrated structure with stable resistance, high tensile strength, excellent vibration resistance and oxidation resistance. It effectively eliminates cold solder joints, virtual welding and wire breakage, fully meeting the application standards of high-voltage and high-current wire harnesses.

2. Cost-Effective and Mass-Production Friendly

A single welding cycle takes only 0.1 to 0.5 seconds with no cooling time required, delivering much higher efficiency than traditional processes. It requires no consumables such as solder or flux, with low power consumption and simplified working procedures. Supporting one-click switching of multiple customized welding formulas, it perfectly adapts to flexible mass production.

3. Safe, Eco-Friendly and User-Friendly Operation

The welding process produces no electric arcs, sparks, harmful fumes or residues, ensuring a safe and eco-friendly working environment. Featuring a touchscreen interface, it supports convenient parameter adjustment and formula access, enabling new operators to get started quickly. Multiple built-in safety protections effectively avoid operational risks.

4. Strong Compatibility and Wide Application Range

It is applicable to welding of various copper and aluminum wire harnesses, including wire-to-wire bonding, wire-to-terminal welding and copper/aluminum sheet laminating, supporting wire sizes up to 160mm². Customized welding heads and fixtures are available to meet the processing requirements of non-standard and special-shaped wire harnesses.

3. Core Configuration and Parameters

Adopting a modular and compact design, the machine is equipped with durable components with low failure rate, suitable for long-term uninterrupted industrial production.

• Core System: Full-digital intelligent ultrasonic generator with automatic frequency tracking and amplitude stabilization, ensuring stable welding power without fluctuation

• Precision Control: High-precision pneumatic and servo control system with accurate pressure and vibration response

• Operation Function: High-definition touch screen supporting formula storage, parameter traceability and data export

• Standard Parameters: Working frequency 20KHz, adjustable power 6000W-14000W, rated voltage 220V, working air pressure 0.5-0.7MPa

• Processing Functions: Wire harness butt welding, squaring, shaping, terminal pressure welding and other processes

• Machine Types: Desktop and vertical styles optional, compatible with standalone operation and assembly line integration, with non-standard customization available

4. Application Scenarios

It is mainly used for high-precision and high-reliability wire harness processing in the following fields:

• New Energy Industry: Welding of power battery wire harnesses, high-voltage connecting wires, battery tabs and bus bars

• Automotive Industry: Welding of automotive high and low-voltage wire harnesses, headlight harnesses and terminal connecting wires

• Home Appliance & Electrical Industry: Welding of internal appliance harnesses, motor leads and electric control terminal wires

• Precision Electronics Industry: Precision butt welding of micro multi-strand harnesses for instruments and communication equipment

• Other Processing: Integration of multi-strand metal wires, bonding of copper and aluminum sheets, and welding of special-shaped terminals

5. Process Advantages

Compared with traditional processes, ultrasonic welding requires no consumables, avoids virtual welding and ensures superior conductivity. Compared with crimping, it achieves tighter bonding with better anti-loosening and anti-oxidation performance. Different from fusion welding, it causes no wire damage or insulation layer damage, delivering a higher finished product yield. It can be well integrated into automated intelligent production lines.

6. After-Sales Support

All machines pass strict aging tests for stable and long-term service. We provide one-stop services including on-site installation, commissioning, operational training and lifelong maintenance. Customized sample testing, process optimization and fixture customization services are also available to support stable and continuous mass production for customers.