4000W Ultrasonic Battery Tab Welding Machine

4000W Ultrasonic Battery Tab Spot Welding Machine for Multi-Layer Foils and Tabs - TOB-USW-4000W

Product Overview and Ideal Applications

The TOB-USW-4000W is a 4000 W ultrasonic battery tab spot welding machine. The machine is used for multi-layer foils with multi-layer tab welding with the stacking process, and it is suitable for both anode and cathode. This welding machine is also suitable for lithium battery PACK process welding - so one platform covers tab welding in cell assembly and welding work at the PACK stage.

The welding system is built around an intelligent digital circuit with an advanced CPU central processing system. The ultrasonic frequency is 20 kHz and the ultrasonic power is 4000 W; the transducer tolerable power is Peak Power 4000 W. The welding time is within 0.2 s per time, the welding pressure is adjustable within 0-1 MPa, and the time control is adjustable within 0-60 s. The tab welding mode is stacked welding, with a tab welding capability of > 0.4 mm, a welding area length of 12 mm, a welding point width of 4 mm, and 4 x 12 mm strip type welding points.

The welding head is made of imported high speed steel. The solder joints height is 0.3 mm, the distribution status of solder joints/patterns is mesh/straight pattern, the height between the welding surface and the welding head is > 6 mm, the welding head length is ≥ 65 mm, 2 pcs of welding area are available for the welding heads, and the welding head installation direction is longitudinal. The adjustable amplitude range is half circle 3-10 µm, and the welding head life is ≥ 50,000 times.

The transducer set is specified for matched operation: the difference in frequency between the transducers is ≤ 400 Hz, the impedance difference between the transducers is ≤ 4 Ω, the capacitance difference between the transducers is ≤ 400 pF, and the insulation resistance of the transducer to the outer shell is ≥ 30 MΩ. The ultrasonic generator uses automatic frequency tracking, with a constant amplitude function from a switching power supply - constant voltage constant current (constant amplitude) - and stepless adjustable amplitude.

Weld quality is defined by the welding result: no virtual welding, no welding penetration, no leakage, welding firm, full and clear solder joints, with damage tore the foil 80% residual on the TAB; the welding tensile strength is ≥ 4 N, and the product pass rate is ≥ 99.8% (under the material is qualified). The equipment design life is 8-10 years, and the welder is arranged as a split set: the generator measures 260 mm x 480 mm x 168 mm and weighs 15-20 kg; the machine head measures 190 mm x 460 mm x 350 mm and weighs 30-35 kg; the machine weighs about 57 kg without table.

Ideal for:

• Battery stacking processes that weld multi-layer foils to multi-layer tabs - the machine is suitable for both anode and cathode.
• Cell assembly and PACK areas that need one welding platform: the machine is also suitable for lithium battery PACK process welding.
• Tab welding tasks with a capability of > 0.4 mm - welding area length 12 mm, welding point width 4 mm, and 4 x 12 mm strip type welding points, in stacked welding mode.
• Weld schedules that require a welding time within 0.2 s, a pressure adjustable within 0-1 MPa, and a time control adjustable within 0-60 s.
• Production lines that specify weld quality targets: welding tensile strength ≥ 4 N and product pass rate ≥ 99.8% (under the material is qualified).

Need to confirm whether the 4000 W / 20 kHz configuration and the stacked tab welding capability match your tab stack and PACK process? Contact our engineers with your foil and tab construction, welding area, and quality targets.

Working Principle and Equipment Components

Ultrasonic metal welding joins the metal sheets at the weld interface rather than by melting the bulk material. The transducer transforms the high-power oscillation signal of supersonic frequency into mechanical energy of corresponding frequency and applies it to the interface of the metal sheet that needs to be fused, so that the metal sheet is heated instantly, and then the particles in the metal lattice are started, so that the molecules in the metal sheet are fused together through mutual penetration.

In the stacking process, the cell's foils are stacked in multiple layers and must be joined to the multi-layer tabs; the TOB-USW-4000W performs this multi-layer foil with multi-layer tab welding, for both anode and cathode. The same machine is also suitable for lithium battery PACK process welding - so the welder serves both the cell assembly stage and the PACK stage.

The metal welding machine is mainly composed of the ultrasonic generator, transducer, mold, pneumatic parts, frame, and so on. The generator drives the transducer with automatic frequency tracking; the pneumatic parts apply the welding pressure, adjustable within 0-1 MPa; and the welding head - installed longitudinally, with an adjustable amplitude range of half circle 3-10 µm - presses onto the tab stack for a welding time within 0.2 s per time.

Key Engineering Characteristics of the TOB-USW-4000W

1. 4000 W / 20 kHz Ultrasonic Welding Platform: The machine runs at an ultrasonic frequency of 20 kHz with an ultrasonic power of 4000 W; the transducer tolerable power is Peak Power 4000 W.
2. Multi-Layer Foil Tab Welding in the Stacking Process: The machine is used for multi-layer foils with multi-layer tab welding with the stacking process, and it is suitable for both anode and cathode - covering both sides of the cell in the same welding platform.
3. Stacked Tab Welding Capability Above 0.4 mm: The tab welding mode is stacked welding, with a tab welding capability of > 0.4 mm, a welding area length of 12 mm, a welding point width of 4 mm, and 4 x 12 mm strip type welding points.
4. Welding Time Within 0.2 s with Adjustable Pressure and Time: The welding time is within 0.2 s per time; the pressure is adjustable within 0-1 MPa and the time control is adjustable within 0-60 s, so the weld schedule can be tuned to the tab stack in production.
5. Imported High Speed Steel Welding Head: The welding head is made of imported high speed steel, with a solder joints height of 0.3 mm and a mesh/straight pattern distribution; the height between the welding surface and the welding head is > 6 mm, the head length is ≥ 65 mm, 2 pcs of welding area are available, and the head is installed longitudinally. The welding head life is ≥ 50,000 times, and the adjustable amplitude range is half circle 3-10 µm.
6. Matched Transducer Set with Consistency Control: The transducer set is specified with a frequency difference ≤ 400 Hz, an impedance difference ≤ 4 Ω, a capacitance difference ≤ 400 pF, and an insulation resistance of the transducer to the outer shell ≥ 30 MΩ - tolerances that keep the welding heads matched when transducers are replaced.
7. Intelligent Digital Generator with Automatic Frequency Tracking: The ultrasonic generator uses automatic frequency tracking; the constant amplitude function is provided by a switching power supply - constant voltage constant current (constant amplitude) - and the amplitude is stepless adjustable. The circuit technology is an intelligent digital circuit with an advanced CPU central processing system.
8. Weld Quality Defined by Appearance, Strength, and Pass Rate: Accepted welds show no virtual welding, no welding penetration, no leakage, firm welding, full and clear solder joints, with damage tore the foil 80% residual on the TAB. The welding tensile strength is ≥ 4 N, and the product pass rate is ≥ 99.8% (under the material is qualified).
9. Also Suited to Battery PACK Process Welding: In addition to cell tab welding, the machine is suitable for lithium battery PACK process welding - one welding platform for both cell assembly and PACK process welding.
10. Split Format and Long Design Life: The generator measures 260 mm x 480 mm x 168 mm and weighs 15-20 kg; the machine head measures 190 mm x 460 mm x 350 mm and weighs 30-35 kg; the machine weighs about 57 kg without table. The equipment design life is 8-10 years.

Complete Technical Specifications

1. Substrate Material

2. Battery Cell

3. Tab Welding

4. Welding Head Standard

5. Transducer

6. Ultrasonic Generator

7. Welding Result

8. Equipment Design Life

9. Equipment Performance Index

10. Equipment Size (For Reference)

Equipment Functional Features

• Intelligent digital circuit, advanced CPU central processing system.
• With energy mode, power mode, and time mode - multiple intelligent control modes.
• Ultrasonic frequency automatic tracking.
• Energy, time, and power with a variety of upper and lower limit quality alarm functions.

Practical Operating Recommendations

• Confirm the weld application before setup: the machine handles multi-layer foils with multi-layer tab welding with the stacking process, for both anode and cathode, and it is also suitable for lithium battery PACK process welding.
• Prepare the supplies: the machine runs on 220 V / 50 Hz, and the welding setup uses an air pressure of 2-5 kg, as listed in the equipment performance index.
• Set the weld schedule: pressure adjustable within 0-1 MPa and time control adjustable within 0-60 s; the welding time is within 0.2 s per time.
• Match the welding head: imported high speed steel head with a solder joints height of 0.3 mm and mesh/straight pattern; the height between the welding surface and the welding head is > 6 mm, the head length is ≥ 65 mm, and 2 pcs of welding area are available for the welding heads.
• Tune the amplitude: the adjustable amplitude range is half circle 3-10 µm; keep the setting within the range and verify the weld on a sample before production.
• Keep transducer sets matched: when transducers are replaced, respect the tolerance windows - frequency difference ≤ 400 Hz, impedance difference ≤ 4 Ω, capacitance difference ≤ 400 pF, and insulation resistance of the transducer to the outer shell ≥ 30 MΩ.
• Use the generator's quality control functions: energy mode, power mode, time mode, frequency automatic tracking, and the quality control upper and lower limit alarms.
• Verify weld results against the acceptance criteria: appearance (no virtual welding, no welding penetration, no leakage, welding firm, full and clear solder joints, with damage tore the foil 80% residual on the TAB), welding tensile strength ≥ 4 N, and product pass rate ≥ 99.8% (under the material is qualified).
• Plan the installation: the generator measures 260 mm x 480 mm x 168 mm and weighs 15-20 kg; the machine head measures 190 mm x 460 mm x 350 mm and weighs 30-35 kg; the machine weighs about 57 kg without table. The equipment design life is 8-10 years.

Engineering FAQ

Q1: What is the TOB-USW-4000W used for? 

The machine is used for multi-layer foils with multi-layer tab welding with the stacking process, and it is suitable for both anode and cathode. The welding machine is also suitable for lithium battery PACK process welding.

Q2: What are the main performance figures of the machine? 

The ultrasonic frequency is 20 kHz, the ultrasonic power is 4000 W, and the air pressure is 2-5 kg. The welding time is within 0.2 s, the voltage is 220 V / 50 Hz, and the weight is about 57 kg, without table.

Q3: What tab welding capability does the machine provide? 

The tab welding mode is stacked welding, with a tab welding capability of > 0.4 mm. The welding area length is 12 mm, the welding point width is 4 mm, and the number of welding points is 4 x 12 mm strip type. The welding time is within 0.2 s per time; the pressure is adjustable within 0-1 MPa, and the time control is adjustable within 0-60 s.

Q4: What welding head does the machine use? 

The welding head material is imported high speed steel. The solder joints height is 0.3 mm, the distribution status of solder joints/patterns is mesh/straight pattern, the height between the welding surface and the welding head is > 6 mm, the welding head length is ≥ 65 mm, and 2 pcs of welding area are available for the welding heads. The welding head installation direction is longitudinal, the adjustable amplitude range is half circle 3-10 µm, and the welding head life is ≥ 50,000 times.

Q5: What are the transducer specifications? 

The difference in frequency between the transducers is ≤ 400 Hz, the impedance difference between the transducers is ≤ 4 Ω, and the capacitance difference between the transducers is ≤ 400 pF. The insulation resistance of the transducer to the outer shell is ≥ 30 MΩ, and the tolerable power is Peak Power 4000 W.

Q6: What generator functions are provided? 

The frequency control mode is automatic frequency tracking. The constant amplitude function is provided by a switching power supply - constant voltage constant current (constant amplitude) - and the amplitude is stepless adjustable. The circuit technology is an intelligent digital circuit with an advanced CPU central processing system, with energy mode, power mode, time mode, frequency automatic tracking, and quality control upper and lower limit alarm functions.

Q7: What are the welding result requirements? 

Appearance: no virtual welding, no welding penetration, no leakage, welding firm, full and clear solder joints, with damage tore the foil 80% residual on the TAB. The welding tensile strength is ≥ 4 N, and the product pass rate is ≥ 99.8% (under the material is qualified).

Q8: What is the equipment design life? 

The equipment design life is 8-10 years.

Q9: How does the ultrasonic welding work, and what are the equipment components? 

The transducer transforms the high-power oscillation signal of supersonic frequency into mechanical energy of corresponding frequency and applies it to the interface of the metal sheet that needs to be fused, so that the metal sheet is heated instantly, and then the particles in the metal lattice are started, so that the molecules in the metal sheet are fused together through mutual penetration. The metal welding machine is mainly composed of the ultrasonic generator, transducer, mold, pneumatic parts, frame, and so on.

Q10: What are the equipment sizes and weights? 

The generator size is 260 mm x 480 mm x 168 mm (W x L x H) and its weight is 15-20 kg; the machine head size is 190 mm x 460 mm x 350 mm (L x W x H) and its weight is 30-35 kg. The machine weighs about 57 kg, without table.

Ready to add ultrasonic battery tab spot welding to your line? Request a quotation for the TOB-USW-4000W with your tab construction, foil materials, and welding area. Our engineers can advise on the transducer and welding head configuration, the amplitude, pressure, and time settings, and the integration of the welder into your stacking or PACK process.

tob.amy@tobmachine.com| +86 181 2071 5609

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