Laser Welding Machine for Prismatic Cell Top Lid and Filling Port Sealing

Battery Model

T(mm)

W(mm)

H(mm)

Blueprint

20-25

100

120

Compatible

12-60

80-170

90-190

Functions

Technical Requirements

Battery Positioning

Battery positioning is done by clamping with a travelling jig and vertical welding.

Battery welding is based on the top (top cover surface).

Repeatable positioning tolerance of positioning fixture: ±0.02mm (repeat clamping Master test), the gap between Master and clamping plate after clamping fixture ≤ 0.04mm.

When positioning in different axes, it is necessary to avoid the sliding friction between the clamping jig and the battery to produce appearance defects.

Positioning and clamping cylinders need to have air pressure monitoring and alarm function, air pressure fluctuation ≤ 0.05Mpa.

The height difference between the upper surface of the fixture and the upper surface of the cover: 1.5-2.0mm.

No metal material can be used in the contact area with the electric core.

Welding

Coaxial blowing protective gas (N2, purity ≥ 99.99%) to prevent welding oxidation, adjustable flow rate (resolution of 0.1L/min), with flow monitoring and alarm functions

Laser head height adjustable, height value visualisation resolution of 0.05mm (for monitoring height offset)

Out-of-focus amount of automatic measurement, abnormal alarm, resolution ≤ 0.05mm

Ring spot laser, 2KW + 1KW, line diameter> 100um/600um, equipped with chiller, laser welding head and transmission fibre laser power fluctuations ≤ 3%, power linearity ≥ 0.99

Laser head X / Y / Z direction repeat alignment tolerance ± 0.02mm, laser head welding speed ≥ 70mm / s, laser head welding movement jitter amplitude ≤ 0.05mm, corner welding speed fluctuations ≤ 10mm / s, trajectory deviation: ± 0.05mm

Laser welding angle adjustable, laser welding can be used 5 ~ 13 ° laser deflection

Effective welding depth 0.5-1.2mm, melt width 0.8-1.4mm;

Pre-welding before full welding (with compression function), 6-8 welded joints

Welding seam pressure ≥ 1.1Mpa; laser alignment repeatability requirements: ± 0.04mm; welding process and transport process can not damage the surface of the aluminium shell and the plastic parts of the top cover pole columns

Welding products for the aluminium shell, shell wall thickness of 0.4-0.8mm, weld appearance and internal weld marks smooth and bright, smooth transition with the base material, no welding, no leakage of welding, no over-welding, no inclusions, no air holes, no bursting points

Welding spatter and fume handling

Self-contained dust removal function

Equipped with welding protective gas device, flow, angle, distance can be adjusted (flow can be traced)

The cross-section of the injection head extends no more than 5mm from the dust suction port

Equipped with dust removal machine, the end of the dust suction port wind speed ≥ 15m / s; welding station with welding slag protection mechanism, no welding slag residue on the surface of the aluminium case

Dust suction pipeline installation of regulating valves, in order to adjust the air volume, wind speed, while the use of stainless steel piping

Dust-absorbing pipeline should be installed with a wind pressure meter, which can monitor the wind pressure in real time, and the wind pressure meter should be associated with the equipment control programme to achieve the function of stopping and alarming when the wind pressure is too high and too low.

Protective cover removal

Protective cover and top cover surface closely fit during the welding process

Prevent the plastic part of the pole from being burnt during the welding process; prevent the surface of the battery from being contaminated by welding spatter; no visible soot residue.

Product switching

Top cover welding and sealing nail welding are integrated in one machine, the switching time of fixtures for different models is ≤30min, easy to disassemble and install, and the switching of products does not affect the positioning accuracy of the fixtures and the service life of the machine.

Functions

Technical Requirements

Battery Positioning

Cylinder up to the reference plate, mechanical limit, the fixture is a spring mechanism;

The bottom of the reference plate is sprayed with 0.1~0.3mm Teflon to ensure contact insulation with the battery.

Fixture precision ≤ 0.1mm

Tolerance of battery alignment after positioning: ±0.5mm.

The height direction of the battery top cover as the positioning reference

Filling Port Welding

With CCD system to capture the position of the sealing nail, capture and positioning system accuracy of ≤ ± 0.03mm, automatic detection of focus resolution: ≤ 0.02mm

Pre-welding: automatic clamping of the battery in the welding position fixture, and through the positioning, pre-welding, pre-welding, pre-welding four quadrant points (which can be dispensed with according to the process)

After the completion of pre-welding, full welding

Adjustable laser welding angle, 5~13° laser deflection can be used during laser welding

Welding process with less spatter, good weld appearance, welding depth of more than 0.5mm, spot diameter (melt pool width) of more than 0.95mm, welding speed: ≥ 6mm / s

Welding seam pressure ≥ 1.1Mpa

Motor positioning, weld offset ≤ 0.05mm

Smooth appearance of welded joints, no burrs, black spots, craters, etc. Welding heat-affected zone is small, the temperature at 2mm from the weld is less than 80℃.

Welding with protective cover to protect the battery welding spatter; welding station fixtures are independently designed to ensure the consistency of each lifting

Real-time extraction of smoke generated during the welding process, equipped with dust removal machine, the use of stainless steel piping, the end of the dust suction port wind speed ≥ 10m / s

Laser head movement stability: speed range of movement, laser head jitter amplitude (X/Y/Z axis) ≤ 0.05mm; laser head alignment repeatability (X/Y axis) ≤ 0.05mm; welding focal length real-time monitoring and compensation of the measured value to the welding Z-axis

Top cover welding and sealing nail welding are integrated with one machine, the switching time of fixtures for different types of products is ≤30min, easy to disassemble and install, and the switching of products does not affect the positioning accuracy of the fixtures and the service life of the machine.