ultrasonic battery metal welding machine analyze

1、ultrasonic battery metal welding machine

(1) The working principle of spot welding machine

The ultrasonic battery metal welding machine uses the high-frequency vibration energy of ultrasonic waves to realize the connection between metals. Specifically, when the ultrasonic generator generates a high-frequency electrical signal, it is converted into a mechanical vibration of the same frequency by a transducer. This high-frequency vibration is transmitted to the welding tool head (welding head) through the amplitude rod, which makes the welding head vibrate at a very high frequency (usually between 20kHz-70kHz). When the welding head acts on the metal material to be welded, the friction between atoms increases sharply under the action of high-frequency vibration on the metal surface, and a large amount of heat is generated. At the same time, under a certain pressure, the oxide film on the surface of the metal is broken, and the pure metal atoms contact and diffuse with each other, thus achieving a firm connection between the metals in the solid state. Compared with traditional welding methods, such as resistance welding and arc welding, ultrasonic welding does not need to add additional solder, nor does it produce a process of melting metal at high temperature, which avoids problems such as changes in the performance of metal materials and welding defects caused by high temperature.

2、 the significant advantages of ultrasonic battery spot welding machine

(1) Excellent welding quality

No heat affected zone: Because ultrasonic welding is carried out in solid state, there is no high temperature melting process, so it will not cause thermal impact on the metal materials around the welding area, avoiding the problem of material deformation and embrittlement caused by thermal stress. This is particularly important for products such as lithium batteries, which require extremely high material properties, to ensure the consistency and stability of the battery, and improve the overall performance and service life of the battery.

Solid welded joint: through high-frequency vibration to make metal atoms mutual diffusion and combination, the formed welded joint high strength, good sealing. In the production of lithium batteries, it can effectively ensure the reliability of the connection between the positive and negative electrodes of the battery and the pole ear, and between the battery modules, reduce the problems such as the increase of the battery internal resistance and the decrease of charge and discharge performance caused by poor connection, and improve the safety and reliability of the battery.

High-precision welding: Ultrasonic welding can achieve very precise energy control and welding parameter adjustment, which can meet the needs of micro-size and high-precision welding. In the process of lithium battery electrode welding, it can ensure the accuracy of welding position and the stability of welding quality, and improve the yield of products.

(2) High production efficiency

Fast welding process: The speed of ultrasonic welding is very fast, and the single welding time is usually between a few milliseconds and tens of milliseconds, which is much faster than the traditional welding method. This makes it possible to greatly improve production efficiency and reduce production costs in large-scale lithium battery production.

Easy automated integration: The operation of the welding machine is relatively simple and can be perfectly integrated with the automated production line. Through the automatic control system, the precise control and monitoring of the welding process can be achieved, improving the consistency and stability of the production process, while reducing manual intervention, reducing the impact of labor intensity and human factors on product quality.

(3) Extensive material adaptability

Compatible with a variety of metal materials: Ultrasonic battery metal welders can weld a variety of metal materials, including common battery metal materials such as aluminum, copper, nickel, and dissimilar metal combinations between them. This provides more material options for the design and manufacture of lithium batteries, which can meet the diverse needs of battery performance in different application scenarios.

Low requirements on the surface state of the material: compared with some traditional welding methods, ultrasonic welding is less sensitive to impurities such as oil and oxide on the surface of metal materials. To a certain extent, it can reduce the pretreatment process of the material surface before welding, simplify the production process, and improve the production efficiency.

3、how to accurately choose the right ultrasonic battery metal welding machine

(1) Clear welding requirements

Battery types and specifications: Different types of lithium batteries, such as lithium-ion batteries, lithium polymer batteries, etc., as well as different battery specifications, their electrode material, electrode size and shape are different. When selecting the welder, it is necessary to determine whether the welding power, amplitude, welding time and other parameters of the welder can meet the requirements according to the specific battery type and specifications. For example, for the welding of large power battery modules, the welder needs to have higher power and greater welding pressure to ensure the robustness of the welding; For small consumer batteries, more attention may be paid to the accuracy and welding speed of the welder.

Production scale and capacity requirements: If it is a large-scale lithium battery production enterprise, it is necessary to consider the production efficiency and automation of the welding machine. Select welders that can be efficiently integrated with automated production lines, with fast welding speed and high stability to meet the needs of large-scale, efficient production. For small-scale production enterprises or laboratory research and development scenarios, you can choose more flexible and cost-effective welding equipment according to actual needs.

(2) Consider the performance of the welding machine

Power and frequency adjustment range: high-quality ultrasonic battery metal welders should have a wide range of power and frequency adjustment functions to adapt to the requirements of different materials and welding processes. The power adjustment range ensures that sufficient and appropriate welding energy is provided when welding metals of different thicknesses and materials; Frequency adjustment helps to optimize the welding effect and avoid welding defects caused by inappropriate frequency. In the selection, it is necessary to ensure that the power and frequency adjustment range of the welder can cover the required parameter interval according to the actual welding needs.

Welding stability and repeatability: welding stability and repeatability is an important indicator to measure the performance of the welding machine. The stable welding process can ensure the consistent quality of each welding and reduce the rate of defective products. When selecting the welder, you can understand the stability of the welder and the repeatability of the welding results during long-term operation by viewing the technical parameters of the equipment, user evaluation and actual testing. For example, some advanced welding machines use intelligent control systems, which can monitor and adjust welding parameters in real time to ensure that the welding process is not interfered with by external factors, so as to ensure the stability of welding quality.

Equipment reliability and maintenance convenience: A reliable welding machine can reduce downtime during production and improve production efficiency. In the selection, we should pay attention to the brand reputation of the welding machine, the production process and the quality of the key parts used. At the same time, the maintenance convenience of the equipment can not be ignored, including whether the replacement of wearing parts is convenient, whether the fault diagnosis of the equipment is simple and fast. Choosing a welding machine with low maintenance cost and small maintenance difficulty can reduce the operating cost and equipment management difficulty of enterprises.

4、ultrasonic battery metal welding machine in lithium battery production of multiple applications

(1) Battery pole ear welding

As a key component of connecting the positive and negative electrodes of the battery with the external circuit, the welding quality of the battery electrode has a direct impact on the charge-discharge performance and safety of the battery. Ultrasonic welding can achieve a solid connection between the pole ear and the pole plate to ensure the stability of current transmission. Whether it is the welding of aluminum lugs and Aluminum Foil, or the welding of nickel lugs and copper foil, the ultrasonic battery metal welding machine can play its unique advantages to ensure the strength and conductivity of the welded joint, and effectively improve the performance and reliability of the battery.

(2) Battery module assembly

In the assembly process of lithium battery modules, multiple single batteries need to be connected together to form a module with a certain voltage and capacity. Ultrasonic welding can be used to connect the bus bar in the battery module to the battery pole, as well as the connection plate and other components inside the module. The module connection achieved by ultrasonic welding has the characteristics of high connection strength, low resistance and strong reliability, which can meet the requirements of the battery module in different working environments and improve the overall performance and safety of the battery module.