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Semi Automatic Battery Tab Welding Machine
Our semi automatic battery tab welding machine is designed for ultrasonic welding of single‑tab or double‑tab cells. This battery tab spot welding equipment automates pre‑weld short circuit testing, pre‑welding, dust extraction, tab cutting, main welding, tape application, and post‑weld short circuit testing. As a lithium battery tab welder for pack assembly, it delivers ±0.5mm positioning accuracy, ≥70N peel force, and ≥60% weld area residue. Available in two models (300 and 900) to accommodate cell lengths from 150mm to 900mm.
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What Is a Semi Automatic Battery Tab Welding Machine?
A semi automatic battery tab welding machine is used to weld electrode tabs (nickel, aluminum, or copper) to battery cell terminals or busbars. It is essential for lithium‑ion battery pack assembly, ensuring low‑resistance, high‑strength electrical connections. Our machine combines manual loading/unloading with automated welding, cutting, and taping – offering high precision and repeatability while keeping equipment costs lower than fully automated lines. It is ideal for small‑to‑medium volume production, R&D labs, and repair stations.
Battery Tab Spot Welding Equipment – Key Technical Features
This battery tab spot welding equipment incorporates the following advanced features:
Pre‑weld short circuit test – Flat pressure test with adjustable pressure and duration; rejects defective cells before welding.
Ultrasonic welding (flat seam) – Optional protective tab welding function available.
Pre‑weld and main weld dust extraction – Prevents weld spatter from entering the cell.
Automatic tab cutting – Integrated waste collection for clean operation.
Automatic tape application – Quick‑change tape mechanism, anti‑sticking, and safety blade protection.
Flexible tooling – Changeover fixtures allow multiple product models; supports both single‑tab and double‑tab cells.
Lithium Battery Tab Welder for Pack Assembly – Model Specifications (300 & 900)
As a dedicated lithium battery tab welder for pack assembly, our machine is available in two models to cover a wide range of cell sizes:
| Parameter | Model 300 | Model 900 |
|---|---|---|
| Cell size (single tab) | L150–260 × W100–210 mm | L150–350 × W150–260 mm |
| Cell size (double tab) | L150–300 × W100–260 mm | L150–900 × W50–150 mm |
| Cell thickness | 5 – 18 mm | 5 – 18 mm |
| Tab weld position accuracy | ±0.5 mm | ±0.5 mm |
| Tab center‑to‑center accuracy | ±0.5 mm | ±0.5 mm |
| Tab cutting positioning accuracy | ±0.5 mm | ±0.5 mm |
| Peel force (post‑weld tab to electrode) | ≥70 N | ≥70 N |
| Weld residue area | ≥60% | ≥60% |
| Tab cutting die life | ≥300,000 strokes (re‑sharpening possible) | ≥300,000 strokes (re‑sharpening possible) |
| Machine dimensions (L×W×H) | 2800×1300×2000 mm | 8000×1800×2000 mm |
| Power | AC380V, 50Hz, 15kW | AC380V, 50Hz, 25kW |
| Air source | 0.5–0.7MPa, 50L/min | 0.5–0.7MPa, 60L/min |
| Weight | 1.5 T | 3 T |
Process Flow & Automation
The semi‑automatic process sequence is as follows:
Manual loading – Operator places the cell into the flat pressure short circuit test station.
Pre‑weld short circuit test – Automatic test with adjustable pressure and time; rejects defective cells.
Pre‑welding (tack weld) – Ultrasonic pre‑weld with dust extraction to prevent spatter.
Tab cutting – Automatic cutting to precise length with waste collection.
Main welding – Ultrasonic main weld with dust extraction.
Automatic tape application – Tape is applied over the weld mark.
Post‑weld short circuit test – Manual or semi‑automatic test to verify insulation.
Manual unloading – Operator removes finished cell.
All welding parameters (pressure, time, energy) are programmable via HMI. Tooling changeover is quick, enabling multiple product models.
Why Choose This System for High‑Reliability Tab Welding?
High weld strength – ≥70N peel force, ≥60% weld residue area ensures low resistance and mechanical integrity.
Precision alignment – ±0.5mm positioning accuracy for weld, tab cut, and tape placement.
Clean process – Dust extraction at pre‑weld and main weld stations prevents contamination.
Dual short circuit testing – Pre‑weld and post‑weld tests catch defects early.
Long die life – Tab cutting dies last ≥300,000 strokes (re‑sharpening possible).
Flexible cell compatibility – Supports single‑tab and double‑tab cells, wide size range.
Two models – Model 300 for medium cells, Model 900 for extra‑long cells (up to 900mm).
Applications
Lithium battery pack assembly – For EVs, e‑bikes, power tools, energy storage systems.
R&D labs and pilot lines – Flexible, low‑volume production with high precision.
Battery repair and refurbishment – Reliable tab welding for re‑worked cells.
🔧 Precision welding – ±0.5mm accuracy, ≥70N peel force, ≥60% weld area.
🧼 Clean & safe – Dust extraction, pre/post short circuit tests, automatic tape application.
📏 Two models – 300 (max 300mm cells) and 900 (max 900mm cells), single/double tab compatible.