Views: 0 Author: Site Editor Publish Time: 2025-07-08 Origin: Site
With the explosive growth of the new energy vehicle (NEV) market, the safety and stability of batteries have become a focal point in the industry. The welding quality of the precision components inside the battery directly determines whether the battery can operate safely and efficiently. However, welding for NEV batteries faces numerous challenges, and traditional welding methods are unable to meet these demands. Laser welding machines, with their unique advantages, have emerged as a key technology to solve these problems.
Three Major Challenges in New Energy Vehicle Battery Welding
1. Special Materials and Oxidation Risks: New energy vehicle batteries extensively use metals such as aluminum and copper, which have low melting points and high thermal conductivity. These materials are highly susceptible to oxidation during welding. Once an oxide layer forms, it can lead to reduced welding strength and increased electrical resistance, thereby affecting battery performance.
2. Precision Structure and High Accuracy Requirements: Battery modules are composed of multiple cells connected in series and parallel, with complex internal wiring and densely packed weld points. The individual cell dimensions are extremely small, and welding accuracy must be controlled within 0.1 millimeter. Otherwise, serious issues such as short circuits may occur.
3. Safety First, Zero Tolerance for Defects: During charging and discharging, batteries generate heat. If there are defects such as porosity or incomplete welding at the weld points, local overheating can easily occur, potentially leading to battery fires or explosions. The requirements for welding quality are extremely stringent.
Four Technical Advantages of Laser Welding Machines
1. Concentrated Energy and Reduced Oxidation: Laser welding machines use focused high-energy laser beams to instantaneously melt the welding material. The welding process is extremely short in duration, and the heat-affected zone is minimal. This effectively reduces metal oxidation, ensuring the strength and conductivity of the weld points. For example, when welding aluminum battery tabs, laser welding can reduce the thickness of the oxide layer by more than 70%.
2. High-Precision Positioning to Meet Precision Needs: The laser beam spot diameter can be as small as 0.05 millimeters, and when combined with a high-precision vision positioning system, it can achieve welding accuracy at the micron level. Even with the densely packed micro weld points inside the battery, precise welding can be achieved, avoiding issues such as misaligned or missed welds.
3. Non-Contact Welding to Prevent Damage: Unlike traditional welding, which requires electrodes or welding torches to contact the workpiece, laser welding is a non-contact process. It does not exert mechanical pressure on the battery cells or internal wiring, thus effectively preserving the structural integrity of the battery.
4. High Degree of Automation, Stable and Reliable: Laser welding machines can be integrated with industrial robots to achieve automated welding. Through pre-programmed processes, they can perform standardized welding on battery modules of different specifications, avoiding quality fluctuations caused by manual operations. This significantly improves production efficiency and consistency.
Solving Battery Welding Challenges with PDKJ Welders
Faced with the complex demands of new energy vehicle battery welding, PDKJ Welders, with years of technical experience, has launched a series of high-performance laser welding equipment. Their products are equipped with advanced laser generation systems and intelligent control systems, which can precisely adjust laser energy and welding speed to suit welding of different materials and specifications. In addition, PDKJ Welders offers customized services, providing one-stop solutions from equipment selection and process debugging to after-sales maintenance based on the production needs of enterprises. If you are struggling with new energy vehicle battery welding challenges, consider learning more about PDKJ Welders and let professional equipment safeguard the quality of your products.
If you have welding machine requirements, please contact Ms. Zhao
E-Mail: pdkj@gd-pw.com
Phone: +86-13631765713
