BATTERY LASER WELDING MACHINE
Fully automated or manually loaded, this laser welding machine can be integrated in high volume battery production lines. It can make cell-to-busbar connections for various battery-module and battery-pack designs.
With its unique engineering and vision that offers the fastest welding speed for batteries, this machine outperforms other laser welding solutions and has the ability to replace over 10 wire bonding machines with a single unit. As a complete solution, it offers advanced features to help you scale up production, including dynamic weld monitoring, vision, robot arms, and a large welding zone.
Benefits of the Battery Laser Welding Machine
Fastest Laser Welding Solution
Laserax units are faster than other laser welding solutions—up to 5 times faster with 100ms per cell. While our high-power laser offers unmatched welding speed, our automation and vision features maximize the laser’s duty cycle.
Robot arms dynamically move clamping tools around so that the amount of time laser welding waits for clamping is minimal. The laser’s large field of view also minimizes the laser head’s mechanical movements. All of this ensures that more time is spent welding to meet your production requirements.
Individual Cell Vision in Batches
Many laser welding solutions analyze cell positioning one cell or few cells at a time. This approach to vision is slow and limits the laser’s uptime, slowing down the machine’s cycle time.
With its large field of view, our vision system analyzes individual cell positions in batches (for example, +150 cells at once for the 21700 format). This provides the perfect balance between precision and speed by reducing the time required for vision. Both clamping and welding positions are compensated by the vision system to meet the precision requirements of batteries.
Real-Time Weld Monitoring
Our laser weld monitoring system combines optical sensors with artificial intelligence to automatically detect weld defects during laser welding. Each weld is analyzed individually, and the types of defects are identified. Defects can then be reworked on the spot—either automatically or through manual operations.
Scalable & Flexible
The machine’s size can be scaled to different battery module, pack, and cell formats. Its design also makes it possible to meet evolving requirements. We use robot arms to dynamically apply pressure on each individual connection. The size and number of robots are adapted to your needs.
If you need to change your busbar design, clamping is easy to adapt. The clamping position can be changed with a simple reprogramming of the robot paths, and the clamping tool can be modified if needed.
Battery Welding Expertise
Our battery and laser welding experts are involved at every step of the project. They can optimize the laser welding performance for your specific application, support your product design phase from a laser welding perspective, assist in preproduction and testing phases, and build battery modules to test your process.
Data Monitoring for Weld Traceability
Detailed data of the welding process for each individual cell is recorded at all times, including temperature, clamping tools, clamping pressure, weld monitoring (LWM) data feedback, and so on. The monitored data is recorded and stored in the machine, and it is accessible to your MES system.
Complete Solution
Our experts look at your complete manufacturing process so that the machine includes everything you need to integrate laser welding in your production line. Accountable for everything, we’re with you every step of the way to make sure integration is a success and performance requirements are met.
Technical Specifications
| Category | Specifications |
|---|---|
| Laser Power | 2000W single-mode continuous-wave (typical for <2mm busbar) 1000-6000W power range available (Single-mode, Multi-mode, Ring-Core) |
| Laser Type | Ytterbium-doped fiber |
| Wavelength | 1070 nm |
| Laser Source MTBF | 100,000 hours |
| Laser Process | Laser welding of busbar for cylindrical and prismatic cells |
| Part Material | Nickel-plated steel, aluminum, copper, stainless steel (all metals) |
| Cooling | Water-cooling (chiller included) |
| Weld to Cell Accuracy (typical) | ± 100 μm (with vision) |
| Tooling/Clamping | Laserax engineered, included module adapted busbar clamping tool on SCARA robots |
| Machine Control | Laserax controller with welding programming interface on operator HMI |
| Communications | Ethernet/IP, PROFINET, EtherCAT, OPC-UA (others available) |
| Power Requirements | 480V/60Hz or 400V/50Hz |
| Power Consumption | 27kW (typical with a 2000W laser source) |
| Operating Temperature | 15°C to 35°C |
| Operating Humidity | < 70% |
| Part Loading Options | Manual Conveyor in/out Conveyor pass-through |
| Vision | Integrated 3D vision system X-Y-Z measurements |
| Fumes Extraction | Included |
| Enclosure | Class-1 certified laser safety enclosure with interlocked doors |
Laser Machine Size
| Standard | Large* | X‑Large* | |
|---|---|---|---|
| Total Welding Area (X-Y) | 1000 x 800 mm | 1800 x 800 mm | 2400 x 1500 mm |
| SCARA Robots Configuration | 1 to 4 | 2 to 4 | 4 to 8 |
| General Dimensions (W x D x H) | 2250 x 2200 x 2600 mm | 2850 x 2200 x 2600 mm | 4500 x 4000 x 3000 mm** |
| Typical Weight | 4000 kg | 5000 kg | 7000 kg |
*Preliminary values, adapted sizes available
**With Class 1 cabin, also available in open design
Welding Process Data and Options
| Category | Specifications |
|---|---|
| Welding Optics Field of View | 400 x 400 mm |
| Welding Speed (typical) | 4 robots: 100ms per cell (2 welds, 21xxx series) 4 robots: 150ms per cell (2 welds, 46xx Series) 4 robots: 300ms per pole (Prismatic) |
| 3D Vision Field of View | 400 x 400 mm |
| Weld Monitoring | Real-time weld monitoring with Precitec LWM system. Weld quality and defect type identification. |
| Tooling/Clamping | SCARA robots with dynamic tooling for individual cell clamping The pressure tip of the clamping tool is adapted to the cell and busbar type |
| Tooling/Clamping Features | Automated clamping position correction from vision feedback Clamping pressure feedback Motorized angle adjustment Shielding gas option Integrated dust extraction |
| Power Meter | Integrated power meter for measurement of laser power in station |
Avoid Unnecessary Downtime with Remote Support
Whether you need on-site or remote support, our engineers and laser experts can rapidly identify the cause of your problems, making sure your production operations are up and running in no time. With the machine’s remote functionalities, remote support is secure and always available.
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