EV Battery Welders - Old

TECH-SONIC is the first manufacturer to develop a highly-advanced servo-controlled ultrasonic metal welder. This includes the ultrasonic spot welding machine for lithium battery assembly. It combines the latest technologies in ultrasonic welding, servo control, user-friendly microprocessor control, and load cell force feedback, providing a 100% digital welding process. These combined technologies create the Closed-Loop Control welding process. 

TECH-SONIC has been involved specifically in lithium battery welding since 1996. Together with EV battery manufacturers, TECH-SONIC has been working on new advanced solutions in welding foil stacks, foil-to-tab, foil-to-busbar, and tab-to-busbar to meet the needs of assembling current and future batteries.

TECH-SONIC has gone beyond the latest ultrasonic metal welding technology by adding servomechanism control to ultrasonic welding. Thus, producing a closed-loop control welding process that responds to the various dynamics of today’s critical welds. Moreover, CLC ultrasonic spot welding machine provides accuracy, repeatability, and reliability. Specialized in the welding of copper or aluminum foils which are a base material as anode and cathode in lithium battery designs. This patent pending line of ultrasonic spot welding machine allows for Dynamic Force and Amplitude Control™. Coupled with multi-step welding to create the optimum welding parameters for the often-challenging foil, tab and busbar welds.

With single-micron resolution linear encoder, CLC ultrasonic spot welding machine is able to detect weld height changes relative to a set tolerance window with greater precision and accuracy than their pneumatic counterparts. For example, TECH-SONIC’s 3.6kW CLC ultrasonic spot welding machine, model US-3620SH. It can detect one single missing or added foil in a stack of eighty (the thickness of a foil is around 10um). Then signal the error to the user before initiating the welding sequence. Typical pneumatic ultrasonic spot welding machine do not have missing or added foil detection capability with such precision.

By compressing the foils or tabs being welded with the soft-touch landing of the ultrasonic horn (sonotrode), CLC ultrasonic spot welding machine can reduce or prevent foil breaks. It also prevents cracks by reducing stress and allows no coating damage by ultrasonic vibration. In pneumatic processes, the top layers of foils are often cracked by the violent descent of the horn.

Conventional pneumatic ultrasonic metal welding machines also need larger, bulkier parts to support the high force produced by the pneumatic cylinder during welding. Such high force requires increased amounts of power of 5.0kW or more to create necessary friction between parts. Higher power also introduces extra stress and wear on the tooling. Thus, increases the likelihood of horn cracking damage and decreases tooling life. TECH-SONIC tooling can extend life cycles depending on material thickness and the size of the horn. This can be achieved by minimizing power requirements and optimizing the amount of energy and force needed to create solid bonds.

The use of optimum force and energy through Dynamic Force and Amplitude Control™ of the ultrasonic spot welding machine opens opportunities for end-users to weld larger stacks of foils with a wider weld area. Welding stacks of foils or tabs to busbar can also be done. Made possible while maintaining the same power need and limiting the rifts surrounding the weld area caused by ultrasonic vibration.