Fiber laser welding machine EV series

automaticfor integrationfor aluminum

Overview
Battery module welding systems are fully automated workstations designed for busbar-to-cell welding of battery cell modules. Configurable for manual loading or conveyor pass-through, these systems support process development, prototyping and low-volume production. Using IPG fiber lasers and optimized laser path programming, configurations such as EV‑Cube achieve welding speeds up to 15 cylindrical cells per second.

Key features

• Automated busbar‑to‑cell welding with configurable part loading (manual or conveyor pass‑through).
• Welding speed: up to 15 cylindrical cells per second (system/configuration dependent).
• Flexible turnkey architecture to support process development, prototyping and low‑volume production.
• Granite base and linear motors for vibration damping, structural stiffness and high‑accuracy motion.

Materials & cell compatibility

• Supported cell types: cylindrical, prismatic, pouch (soft‑pack).
• Common welded materials: copper, aluminum, nickel, stainless steel, nickel‑plated steel, nickel‑plated copper and dissimilar material combinations.

System options & tooling

• Optional custom tooling development to increase part yield across cell formats.
• IPG custom‑designed tooling; in many configurations the system accepts certified 3rd‑party tooling.
• Module handling options: manual load or conveyor pass‑through with automated entry/exit doors.

Product quality & real-time measurement
Optional in‑process weld measurement directly measures weld penetration depth for each weld to enable 100% weld verification. Real‑time monitoring detects process drift and verifies penetration into the cell casing to reduce risk of part failures and recalls.

Lasers & beam delivery

• Laser types optimized for application: continuous wave (CW), quasi‑CW, pulsed and Adjustable Mode Beam (AMB).
• Dual‑beam laser options with single‑mode core powers up to 3 kW for high‑speed welding.
• Beam delivery options: fixed beam, scanning beam and wobble (oscillating) welding heads.

Mechanical & motion design

• Granite base for vibration damping and structural stiffness to enable stable busbar welding.
• Linear motors for high positioning accuracy and increased system speed.
• Module capacity example: accommodates modules up to ~1 × 1 m and weights up to ~450 kg (configuration dependent).

Software & controls

• Preloaded, tested operator software providing programming and HMI interface (e.g. HMI2 or PLC‑based controls depending on model).
• Control options and recipes support rapid deployment and process repeatability.

Comparison (selected specifications)
Specification — EV‑Cube System — EV‑Flex System
Cell Type: Cylindrical, Prismatic, Pouch — Cylindrical, Prismatic, Pouch
Welding Speed: 15 Cells per Second — 4+ Cells per Second
Max Module Size: 1100 L x 1100 W x 600 H (mm) — 1200 L x 1000 W x 300 H (mm)
Materials: Aluminum, Copper, Steel, Dissimilar — Aluminum, Copper, Steel, Dissimilar
Weld Position Accuracy: ±50 μm — ±250 μm
XY Positioning Repeatability: ±10 μm — ±10 μm
Module Loading: Manual or Conveyor Pass‑Through — Manual or Conveyor Pass‑Through
Tooling: IPG Custom‑Designed Tooling — IPG Custom‑Designed & 3rd‑Party Tooling
Control Software: HMI2 — Siemens 3‑Axis PLC Control
Dimensions: 2600 L x 2200 W x 1800 H mm — 3500 L x 2500 W x 2900 H mm

Applications & value

• Designed for EV battery module manufacturers requiring high‑speed busbar‑to‑cell welding.
• Delivers process development, programming and application support to accelerate deployment.
• Optional tooling and process services maximize yield for cylindrical, prismatic and pouch cell designs.

Technical specifications

• Maximum welding speed: up to 15 cylindrical cells per second (configuration dependent).
• Supported cell types: cylindrical, prismatic, pouch.
• Typical max module footprint (EV‑Cube example): 1100 × 1100 × 600 mm.
• Max module weight supported: up to ~450 kg (system option dependent).
• Weld position accuracy (EV‑Cube): ±50 μm; XY repeatability: ±10 μm.
• Materials welded: aluminum, copper, steel, dissimilar combinations, nickel and nickel‑plated variants.
• Optional in‑process real‑time weld measurement for 100% verification.
• Available laser modes: CW, quasi‑CW, pulsed, AMB; dual‑beam single‑mode powers to 3 kW.
• Beam delivery: fixed, scanning, wobble welding heads.
• Mechanical: granite base, linear motors for high stability and speed.
• Control/software: preloaded HMI2 or PLC options depending on model.