ACEY 6000W Desktop Ultrasonic Metal Welder For Battery Tabs Welding

6000W Desktop Ultrasonic Metal Welder For Aluminum-to-Nickel Battery Tab Welding

Product Description

ACEY-UWM-20-6000 Ultrasonic Metal Welder is designed for aluminum-to-nickel-plated copper welding in pouch cell and battery PACK assembly. It is suitable for connecting aluminum battery tabs to nickel-plated copper terminals, providing a stable weld with low electrical resistance and a clean, flat welding surface.

Equipped with a digital intelligent ultrasonic generator, a high-rigidity steel welding head and specially designed upper and lower welding tools, the machine supports time, energy and segmented welding modes. It can be operated manually by foot pedal or integrated into an automated battery assembly line through I/O signal control.

Main Applications
ACEY-UWM-20-6000 ultrasonic metal welding machine is suitable for:

• Pouch cell aluminum tab welding
• Aluminum-to-nickel-plated copper connections
• Battery terminal welding
• Battery module assembly
• Power battery PACK production
• Standalone manual welding stations
• Semi-automatic battery assembly lines
• Fully automatic battery production lines

Product Features

1. Digital Intelligent Ultrasonic Generator
The full-digital full-bridge circuit provides stable output and strong welding capability. It includes energy feedback, automatic frequency tracking and an RS-485 communication interface for process monitoring and production-line integration.

2. Multiple Welding Modes
The machine supports time mode, energy mode and segmented welding mode. Welding parameters can be stored and recalled, making it easier to switch between different battery products and welding processes.

3. Welding Curve Monitoring
Voltage, current and power curves can be displayed and compared to help operators monitor welding performance, evaluate process stability and optimize welding parameters.

4. High-Rigidity Welding Head
The welding head uses a precision guide-column steel structure with good resistance to torsion. This design supports fast and stable vertical movement while maintaining consistent welding pressure and positioning.

5. Adjustable Welding Parameters
Ultrasonic amplitude can be adjusted from 10% to 100%, while the welding pressure can be set from 0.1 to 0.6 MPa. The typical welding time is between 0.1 and 0.8 seconds, with a programmable range of 0 to 60 seconds.

6. Durable Customized Welding Tools
The upper and lower welding tools are made from selected high-speed steel and processed using professional heat-treatment technology. Their surface patterns can be customized according to the material, thickness, tab width and required welding area.

7. Integrated Cooling and Safety Protection
An integrated cooling system supports stable operation during repeated welding cycles. Photoelectric detection is also included to provide additional protection around the welding area.

8. Reliable Welding Results
Under suitable material and process conditions, the machine produces firm, low-resistance joints with clear welding patterns and flat surfaces. It is designed to reduce false welding, missed welding, weld-through, powder generation, tab cracking and damage to the separator or insulating adhesive.

9. Flexible Standalone or In-Line Operation
The manual configuration is controlled by a foot switch, while the production-line version can be controlled through I/O signals. Its split structure also simplifies transportation, installation and maintenance.

10. Designed for Battery Tab Welding
The machine is primarily intended for welding pure aluminum sheet to nickel-plated copper sheet in pouch cell, battery module and high-capacity battery PACK production.

Supported Welding Process

The standard process described in the specification is intended for connecting:

The equipment is designed for single-layer transition welding. Typical welding sizes include:

The number of cells connected in series or parallel is not specifically limited. Compatibility mainly depends on the material combination, tab dimensions, weld-area design and production-line layout.

Technical Specifications

Product Display

Welding Effect Display

Machine Configuration

The ultrasonic welding system mainly consists of:

• Digital ultrasonic generator
• Ultrasonic transducer system
• Upper welding tool
• Lower welding tool
• Pneumatic components
• High-rigidity welding head
• Machine frame
• Integrated cooling system
• Foot switch for manual operation

Welding Tool Service Life

The upper and lower welding tools are consumable components. Actual tool life may vary according to the welded material, thickness, surface condition, welding pressure, amplitude, operating frequency and maintenance condition.

Operation and Line Integration

• Manual Operation

The standalone machine is controlled by a foot switch. Its standard manual welding-head stroke is approximately 10–15 mm.

• Automated-Line Operation

For production-line integration, the welding cycle can be controlled through I/O signals. The welding-head stroke can be designed between 25 and 45 mm according to the production-line layout and product requirements.

• Process Data Management

Quality Inspection and Acceptance

• Tear and Residual-Bond Test

The welded joint can be torn apart to inspect the remaining bonded area and confirm penetration between the metal layers.

• Tensile-Force Test

For a reference welding size of 25 × 3 mm, the destructive tensile force should be greater than 80 N.

• Trial Welding

Maintenance Recommendations
The upper and lower welding tools should be checked regularly for wear, surface contamination and material adhesion. Production should not continue with severely worn or contaminated welding surfaces.

To maintain stable welding quality:

• Verify welding parameters before production
• Perform trial welding every day
• Keep the compressed air clean and dry
• Check the cooling system regularly
• Inspect the welding tools for wear and adhered material
• Maintain consistent product dimensions and materials
• Carry out weekly equipment maintenance
• Ensure operators receive appropriate training

FAQ

1. What is the ACEY-UWM-20-6000 used for?
It is mainly used for ultrasonic welding of aluminum battery tabs to nickel-plated copper terminals in pouch cell, battery module and battery PACK production.

2. What materials can this ultrasonic welding machine weld?
The standard process is designed for welding 0.30 ± 0.05 mm pure aluminum sheet to 0.20 ± 0.05 mm nickel-plated copper sheet.

3. What welding modes are available?
The machine supports time mode, energy mode and segmented welding mode. Welding parameters can be stored and recalled for repeated production.

4. Can the machine be integrated into an automatic production line?
Yes. The automated-line version can receive I/O control signals, and the RS-485 interface supports communication and process-data integration.

5. What power supply is required?
The machine requires single-phase AC 220 V ±10%, 50 Hz power, a 16 A socket and reliable grounding.

6. What compressed-air supply is required?
Dry and clean compressed air at approximately 0.6 MPa is required. The standard air-tube connection has a diameter of 8 mm.

7. Can welding pressure and amplitude be adjusted?
Yes. Welding pressure can be adjusted from 0.1 to 0.6 MPa, while ultrasonic amplitude can be set from 10% to 100%.

8. Can the welding tools be customized?
Yes. The welding-tool pattern and dimensions can be designed according to the tab material, thickness, width, welding area and available installation space.

9. How is welding quality inspected?
The welded joint can be evaluated through a tear-and-residual-bond test or a tensile-force test. For a reference weld size of 25 × 3 mm, the specified tensile force is greater than 80 N.

10. How long do the welding tools last?
For aluminum-to-nickel-plated copper welding, the reference service life is more than 50,000 cycles per tool. Actual service life depends on the material, process parameters and maintenance condition.

11. What is the difference between the manual and in-line versions?
The manual version uses foot-switch control and has a standard head stroke of 10–15 mm. The in-line version uses I/O control and can have a stroke of 25–45 mm depending on the production-line design.

12. What maintenance is required?
Daily trial welding and regular inspection of the welding tools are recommended. The cooling system, pneumatic components, material consistency and welding parameters should also be checked regularly.