6000W Ultrasonic Battery Tab Welder
Model No.: ACEY-UWM-20-6000
Package: Plywood Case
Product Origin: China
Warranty: One-year warranty with lifetime support
Payment: T/T, Western Union, PayPal, Ali Trade Assurance
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6000W Ultrasonic Battery Tab Welder for Aluminum Nickel-Plated Copper
Product Description
The ACEY-UWM-20-6000 is a high-power ultrasonic welding system developed for joining conductive metal components in lithium battery manufacturing. It is particularly suited to aluminum battery tabs and nickel-plated copper terminals used in pouch cells, battery modules, and high-capacity battery PACKs.
The welding system combines a digital ultrasonic generator, pneumatic welding head, customized upper and lower tooling, and programmable process controls. It can be operated as a standalone workstation using a foot switch or configured for integration into an automated battery production line through I/O control.
Application：
- Pouch cell aluminum tab welding
- Aluminum-to-nickel-plated copper joining
- Battery terminal connections
- Battery module assembly
- High-capacity battery PACK manufacturing
- Battery current-collector connections
- Manual battery welding stations
- Semi-automatic battery assembly systems
- Automated battery production lines
Features
1. 6000W Ultrasonic Power
The high-power ultrasonic generator provides the energy required for demanding metal-to-metal battery tab applications. The system operates at a nominal ultrasonic frequency of 20 kHz.
2. Digital Process Control
A digital control system provides automatic frequency tracking and supports programmable welding parameters. Multiple parameter sets can be stored for different battery products and recalled when required.
3. Three Welding Control Modes
The machine supports time, energy, and segmented welding modes, allowing the welding process to be configured according to the material combination and required joint characteristics.
4. Adjustable Amplitude and Welding Pressure
Ultrasonic amplitude can be adjusted from 10% to 100%, while pneumatic welding pressure can be set from 0.1 to 0.6 MPa. These parameters allow the welding process to be adapted to different tab dimensions and material conditions.
5. Welding Curve Monitoring
Voltage, current, and power curves can be monitored during the welding process. This provides useful process information for parameter adjustment and welding consistency evaluation.
6. Customized Welding Tooling
The upper and lower welding tools can be designed according to the tab material, thickness, width, welding area, and product structure. This makes the machine adaptable to different battery tab configurations.
7. Manual or Production-Line Operation
For standalone use, the welding cycle can be activated with a foot switch. For automated equipment, I/O signals can be used to integrate the welding unit into a larger battery assembly system.
8. RS485 Communication
The RS485 interface provides an option for communication and process-data integration with external production control systems.
Supported Welding Materials
The standard welding configuration is designed for:
| Material | Reference Thickness |
|---|---|
| Pure Aluminum Sheet | 0.30 ± 0.05 mm |
| Nickel-Plated Copper Sheet | 0.20 ± 0.05 mm |
The recommended material combination should be confirmed through sample welding before production. Final compatibility depends on material properties, tab dimensions, surface condition, welding area, amplitude, pressure, and process settings.
Product Specification
| Parameter | Specification |
| Model | ACEY-UWM-20-6000 |
| Equipment Type | Ultrasonic Metal Welding Machine |
| Main Application | Aluminum-to-Nickel-Plated Copper Welding |
| Maximum Input Power | 6000 VA |
| Ultrasonic Frequency | 20 kHz ± 200 Hz |
| Frequency Control | Automatic Frequency Tracking |
| Welding Modes | Time / Energy / Segmented |
| Typical Welding Time | 0.1–0.8 s |
| Programmable Welding Time | 0–60 s |
| Welding Pressure | 0.1–0.6 MPa |
| Amplitude Adjustment | 10–100% |
| Manual Head Stroke | 10–15 mm |
| Automated-Line Head Stroke | 25–45 mm |
| Drive Type | Pneumatic |
| Manual Control | Foot Switch |
| Production-Line Control | I/O Signal |
| Communication | RS485 |
| Power Supply | AC 220 V ±10%, 50 Hz |
| Recommended Air Pressure | 0.6 MPa |
| Air Requirement | Clean, Dry Compressed Air |
| Air Tube | 8 mm |
| Air Consumption | Approx. 0.6 m³/h |
| Machine Structure | Split All-Metal Construction |
Product Display
FAQ
What is a 6000W ultrasonic battery tab welder used for?
The ACEY-UWM-20-6000 is primarily designed for joining conductive battery components, especially aluminum tabs to nickel-plated copper terminals used in pouch cells, battery modules, and battery PACKs.
What materials can this ultrasonic welder join?
The standard configuration is designed for pure aluminum sheet and nickel-plated copper sheet. Other conductive metal combinations may be evaluated through sample welding before production.
What is the ultrasonic frequency of this machine?
The machine operates at a nominal frequency of 20 kHz ± 200 Hz with automatic frequency tracking.
Can the 6000W ultrasonic welder be integrated into an automatic production line?
Yes. The automated configuration supports I/O signal control and can be integrated with battery assembly equipment. RS485 communication is also available for process-data integration.
Does the machine require solder or flux?
The ultrasonic welding process does not require conventional solder or flux for the standard metal joining application.
How should the welding parameters be selected?
Welding time, amplitude, pressure, tooling pattern, and energy should be established through sample trials using the actual tab material, thickness, width, and welding area. Production parameters should be validated before mass production.
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