Is It More Efficient To Use Multiple Spot Welding Machines Or A Single Robot Laser Welding Machine for The Large Welding Area of Battery Trays in New Energy Commercial Vehicles?

The battery trays for new - energy commercial vehicles are large - sized (commonly over 1.5 meters ×2.0 meters), with long weld seams and dense weld points. Welding efficiency directly determines production capacity. Many manufacturers are struggling with whether to use multiple spot welding machines for collaborative operation or whether a single robot laser welding machine is more efficient. In actual production scenarios, robotic laser welders demonstrate a more significant efficiency advantage in large - area welding.

Let's first examine the limitations of using multiple spot welders. Spot welders require electrode contact for welding, and each device can only handle 1 - 4 weld points at a time. For the long straight or circular weld seams of the tray, multiple devices need to be distributed across different workstations, and manual labor or simple robotic arms are required to move the workpiece. This mode has obvious shortcomings: first, it is difficult to coordinate the workstations, and the synchronization rate of multiple devices is low, which can easily lead to workpiece deformation due to disordered welding sequences; second, there is a lot of manual intervention, with frequent adjustments needed for the workpiece position. A single spot welder can only complete 2 - 3 meters of weld seam per hour, and even with 10 devices working together, it is hard to exceed 25 meters/hour. Moreover, labor costs increase with the number of devices.

Now let's look at the efficiency advantages of robotic laser welders. Equipped with high - power laser sources (3000W - 6000W), robotic laser welders can achieve continuous seam welding without the need for point - by - point operations. For the long weld seams of the tray, the welding speed can reach 3 - 5 meters/minute, easily exceeding 150 meters of weld seam per hour, which is more than 50 times that of a single spot welder. Their 6 - axis or 7 - axis robotic arms have a large operating radius and can easily cover a tray of 1.5 meters ×3.0 meters, completing the welding of the entire area without moving the workpiece, thus eliminating the time needed for workstation switching.

In mass production, the continuity advantage of robotic laser welders is even more prominent. A battery tray typically requires welding of multiple parts, such as stiffeners, edges, and base plates. A robot can preset 10 - 20 welding programs, and it only takes 8 - 12 minutes to complete the welding of an entire tray. In contrast, multiple spot welders need to operate in separate procedures, and just the workpiece transfer and model - change debugging can take 5 - 8 minutes per tray, with the total time for a single tray often exceeding 20 minutes. Additionally, robotic laser welders have no electrode wear and only require 30 minutes of maintenance per day, while spot welders need electrode replacement every 2 - 3 hours, resulting in an effective working time that is more than 20% less than that of robots.

In terms of cost, although the initial investment for a robotic laser welder is higher than that for a single spot welder, it is 30% - 40% lower than the total investment for 10 spot welders. Moreover, it can replace 4 - 6 operators, with the cost difference being recouped within half a year to a year.

For large - area welding of new - energy commercial vehicle battery trays, where high efficiency and stability are core requirements, PDKJ's robotic laser welder, with its sufficient power and large operating radius, can quickly complete long - seam welding. It offers flexible program adaptation and low maintenance costs, significantly improving tray welding efficiency and making it the preferred equipment for mass production.

If you have welding machine requirements, please contact Ms. Zhao

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713