High-Power 20kHz Ultrasonic Welding Machine for Pouch Battery Packs

The ultrasonic welding system consists of an ultrasonic generator, transducer, welding mold (horn), pneumatic components, machine frame, and other parts.

 

Working Principle:

The transducer converts the high-power ultrasonic frequency oscillating signal generated by the ultrasonic generator into mechanical energy of the corresponding frequency. This energy is applied to the interface of the metal sheets to be welded. At this interface, heat is instantly generated, causing the particles in the metal lattice to activate. As a result, the molecules at the joining interface permeate into each other and form a solid weld.

 

I. Customer Welding Process Requirements & Corresponding Applicable Product Specifications

Item	Name
Substrate	20KHz（3000W）
1.1 Negative Electrode
1.1.1 Substrate (electrode sheet) material	Copper foil
1.1.2 Substrate  (electrode sheet) thickness	6-12um
1.1.3 Tab (ear) material	Nickel strip
1.1.4 Tab (ear) thickness	0.01-0.1mm
1.2 Positive Electrode
1.2.1 Substrate (electrode sheet) material	Aluminum foil
1.2.2 Substrate (ear) thickness	9-16um
1.2.3 Tab (ear) material	Aluminum
1.2.4 Tab (ear) thickness	0.01-0.1mm
1.3 Other material
1.3.1 Fe plate thickness	no more than 1mm
Cell
2.1 Cell structure	Winding or stacking
2.2 Number of layers	10–60 layers (subject to actual welding)  (4mm × 10mm weld mark)
Welding Process
3.1 Welding method	Direct welding
3.2 Weld mark area	(subject to actual welding by the customer)
Welding Horn and Anvil
4.1 Horn material	Imported high-speed steel
4.2 Horn tooth pattern shape	Upper welding head: serrated pattern (can be modified based on actual welding process)
4.3 Horn length	(subject to customer requirements)
4.4 Usable welding surface of horn	2–4 usable surfaces
4.5 Horn service life	Negative electrode > 300,000 times, Positive electrode > 400,000 times
4.6 Anvil material	High-speed steel
4.7 Anvil tooth pattern shape	Mesh pattern (can be modified based on actual welding process)
4.8 Usable positions of anvil	1 piece
4.9 Anvil service life	Approx.: Negative electrode > 300,000 times, Positive electrode > 400,000 times
4.10 Stroke of the horn	30mm
Transducer
5.1 Transducer frequency	20KHz±0.15KHz
5.2 Transducer power	3600W (peak)
Ultrasonic Generator
6.1 Ultrasonic power	≤3600W (peak)
6.2 Frequency tracking range	20KHz±1KHz
6.3 Frequency tracking method	Automatic real-time frequency tracking
6.4 Welding functions	Supports time and energy control modes
6.5 Pressure adjustment range	0MPa–1MPa, adjustable
6.6 Time adjustment range	0–60s, adjustable
6.7 Welding time	≤0.5S
6.8 Amplitude adjustment range	10%~100%
6.9 Quality control functions	Equipped with frequency, power, energy, and amplitude upper/lower limit alarm and shutdown functions.
6.10 Input voltage	220V ±10% AC (50/60Hz, single phase)
6.11 Welding Data Storage	The machine is equipped with memory to record and store welding data history.
6.12 Adjustable Welding Energy	Welding energy can be adjusted according to process requirements.
6.13 Welding Power Display	The machine can display the power of each welding operation.
Quality
7.1 Welding quality	Inter-layer fusion, firm welding, no missed or false welds, no cracks in the weld area or surrounding regions
7.2 Yield rate	≥99.5% (with consistent incoming materials)
7.3 Equipment Designed Service Life	10 years
7.4 Standard Accessories Included	One set of tools included.
7.5 Warranty	1-year warranty for the main unit, including welding head; consumables excluded.

 

II. Product Information

A. Utilizes advanced constant current and constant voltage circuit technology; ultrasonic amplitude is continuously adjustable.

B. Equipped with intelligent ICS chassis control system with secondary ultrasonic function; system performs self-diagnosis at startup, segmented intelligent amplitude output, and real-time automatic tracking.

C. The welding head’s mechanical structure adopts German-style X-axis guide rail design for extremely high precision.

D. Protection System:

1) Voltage protection system (supply voltage range: 220V–250V); output power and working frequency remain unaffected during automatic voltage stabilization.

2) Overload protection system

3) Overcurrent protection

4) Automatic compensation for unstable supply frequency

5) Feedback system for welding overload protection

 

III. General equipment configuration and standards

1) Noise Level:Measured at 1 meter from the equipment’s outer wall. Noise level during normal operation: <75dB.

2) Operating Environment:

3) Ambient Temperature: 20±5°C

4) Relative Humidity: 60% RH

5) Site must be free from corrosive gases/liquids and explosive gases.

6) Factory load-bearing capacity: ≤800kg/m2.

 

IV. Equipment Dimensions

1) Generator Dimensions (L × W × H): 550mm × 300mm × 550mm

2) Welding Head Dimensions (L × W × H): 480mm × 200mm × 380mm