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Fully Automatic Prismatic Battery Tab Welding Machine
Prismatic tab welder & cutter. High precision, ultrasonic tracking, dust removal, multi-position taping for prismatic LiB cells.
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Fully Automatic Prismatic Battery Tab Welding Machine – Ultrasonic Tab Welder & Electrode Cutter for Prismatic Cell Assembly
⚡ Key Performance: 25-30 PPM | ±0.15mm tab spacing accuracy | ±0.2mm tape attaching | 4.5KW power | Ultrasonic welding with digital frequency tracking | MES-ready
Product Overview – Prismatic Cell Tab Welding Machine
PPCELL’s fully automatic prismatic battery tab welding machine is a high-performance ultrasonic tab welding system designed for efficient tab welding, multi-position taping, and precision electrode cutting in prismatic lithium-ion cell assembly. This automatic electrode cutting machine ensures accurate electrode length control (300–2500mm), consistent tab spacing (±0.15mm), and reliable ultrasonic welding with digital frequency tracking and energy feedback. Ideal for EV, ESS, and industrial battery production lines.
Key Features – Prismatic Tab Welding Equipment
- Precision Ultrasonic Welding: Digital frequency tracking and energy feedback ensure consistent, reliable weld strength with minimal heat input – critical for protecting sensitive cell components. Ultrasonic power ranges from 800W to 8000W, supporting single-layer foil up to 120-layer stacks.
- Multi-Position Tape Attaching: Automatically applies protective tape to weld joints with ±0.2mm accuracy, preventing short circuits and improving cell safety.
- High-Speed Production: 25-30 PPM throughput (at 500mm electrode length), maximizing output for high-volume prismatic cell manufacturing.
- Comprehensive Dust Removal: Pre-welding and post-welding dust extraction (upper and lower sides) ensures clean weld surfaces and reduces contamination-related defects.
- Automatic Tab Feeding & Cutting: Integrated tab feeding, cutting, and rewinding functions with precise electrode length control (300–2500mm).
- Smart Process Corrections: Pre-welding correction, tape attaching correction, and pre/post-cutting movement correction improve yield and reduce scrap.
- Network Bus Remote Operation: Digital parameter adjustment with MES integration for real-time monitoring and full traceability.
- Optional Automation Modules: Automatic rewinding and automatic material collection functions for enhanced production efficiency.
Technical Specifications – Prismatic Tab Welding Machine
| Parameter | Specification |
|---|---|
| Machine Dimensions (L×W×H) | 1800 × 1200 × 1720 mm |
| Power Supply | 4.5 KW |
| Equipment Weight | 1600 KG |
| Electrode Width Range | 30 – 130 mm |
| Electrode Length Range | 300 – 2500 mm |
| Production Efficiency | ≥25 – 30 PPM (Electrode Length 500mm) |
| Tape Attaching Accuracy | ±0.2 mm |
| Tab Spacing Accuracy | ±0.15 mm |
| Tab Length Accuracy | ±0.2 mm |
| Welding Method | Ultrasonic with digital frequency tracking |
| Dust Removal | Pre-weld & post-weld (upper and lower sides) |
| Control System | PLC + HMI, MES integration |
| Optional Features | Automatic rewinding, automatic material collection |
Why Ultrasonic Welding for Prismatic Battery Tabs?
Ultrasonic metal welding is the preferred method for prismatic battery tab connections due to its unique advantages over resistance or laser welding:
- Low Heat Input: Solid-state process avoids melting, eliminating heat-affected zones that can damage separator materials and electrode coatings – critical for prismatic cell safety.
- Superior Conductivity: Creates near-zero resistance joints through direct metal-to-metal bonding without intermetallic compounds.
- High Efficiency: Weld cycles of 0.2-0.5 seconds, delivering up to 30 times lower energy consumption than resistance welding.
- Excellent Multi-Layer Capability: Handles stacks of thin copper/aluminum foils without thermal damage, ideal for high-energy-density prismatic cells.
- No Filler Materials or Flux: Clean, environmentally friendly process with no fumes, sparks, or pollution.
FAQ – Frequently Asked Questions
Q1: What is the difference between ultrasonic and resistance welding for prismatic battery tabs?
Ultrasonic welding uses high-frequency vibrations to create solid-state bonds without melting, preserving electrode coatings and separator integrity. Resistance welding passes electrical current through the joint, generating localized melting and a heat-affected zone that can damage sensitive materials. Ultrasonic is preferred for prismatic cells due to its minimal thermal impact.
Q2: What materials can this tab welding machine handle?
The machine supports aluminum tabs for cathodes, nickel-plated copper tabs for anodes, and multi-layer combinations (aluminum-copper, nickel-aluminum). It also accommodates pre-welding dust removal and tab flattening functions for copper-foil-to-nickel-tab or aluminum-foil-to-aluminum-tab applications.
Q3: Can the machine be integrated with my MES system?
Yes. Our tab welding machine supports network bus remote operation with digital parameter adjustment. Real-time data upload (weld energy, force, displacement, inspection results) is available via Ethernet/IP or Modbus TCP, enabling full traceability and SPC analysis.
Q4: How accurate is the tape attaching function?
The tape attaching accuracy is ±0.2mm. The system applies protective tape over weld joints, preventing short circuits and improving cell safety. Tape width and position are programmable for different tab configurations.
Q5: What is the expected tool life for ultrasonic welding sonotrodes?
Sonotrode life varies by material and application, typically 500,000-1,000,000 welds before requiring re-tipping. Horn life is benchmarked at ≥500,000 welds for cathode and ≥160,000 welds for anode in production environments. Regular maintenance (cleaning, tip inspection) extends service life. Replaceable wear parts are available from PPCELL’s spare parts inventory.
Q6: How does the dust removal system work?
The machine features integrated dust extraction at pre-weld (upper/lower sides) and post-weld stations. High-efficiency vacuum ports capture particles generated during cutting and welding, preventing contamination of downstream assembly processes and improving operator safety.
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Our tab welding experts can help you select the right machine configuration for your prismatic cell format and production target. We provide free technical consultation, on‑site commissioning, and operator training.