Product classification
· Equipment Name: Battery Case Insertion and Top Cap Pre-Welding Equipment
· Model: HY-CIW8080
· Application: Automated insertion of battery cells into protective cases and precise pre-welding of top caps to ensure structural integrity before final welding. Suitable for prismatic and pouch batteries.
Mechanical Specifications
· Equipment Dimensions:
o Length: 2000 mm
o Width: 1500 mm
o Height: 1900 mm
· Weight: 1500 kg ± 5%
· Frame Material: Reinforced steel frame with powder coating for durability.
· Worktable Material: Anodized aluminum alloy with anti-static surface.
· Motion System: Servo-driven X-Y-Z axes with precision linear guide rails.
Case Insertion Specifications
· Insertion Accuracy: ±0.1 mm.
· Cell Compatibility:
o Width: 50–100 mm.
o Height: 50–200 mm.
o Thickness: 5–20 mm.
· Insertion Speed: Up to 10 cases per minute (process-dependent).
· Grip Mechanism: Pneumatic or servo-controlled gripper with adjustable force for different cell materials.
· Case Materials: Aluminum, stainless steel, and polymer.
Top Cap Pre-Welding Specifications
· Welding Technology:
o Laser Welding (standard).
o Optional: Ultrasonic or Resistance Welding.
· Laser Power: 500–2000 W (adjustable).
· Welding Spot Size: 0.2–0.5 mm (programmable).
· Pre-Welding Accuracy: ±0.05 mm.
· Cap Material Compatibility: Aluminum, nickel, and copper.
· Pre-Welding Speed: Up to 8 welds per minute.
Vision and Alignment System
· Alignment Accuracy: ±0.03 mm.
· Camera:
o Type: Industrial-grade CCD camera.
o Resolution: 5 MP with real-time defect detection.
· Lighting: Adjustable LED for enhanced visibility of cases and caps.
· Inspection Features:
o Pre-insertion cell alignment.
o Post-welding inspection for proper cap positioning and weld integrity.
Control and Interface
· Control System: PLC with integrated HMI for seamless operation.
· Interface:
o 12-inch touchscreen with intuitive UI.
o Multi-language support (English, Chinese, others).
· Programmable Parameters:
o Case insertion speed and force.
o Welding power, duration, and spot size.
o Recipe storage for various battery types and sizes.
· Data Logging:
o Internal Capacity: 1 TB for process records.
o Export Formats: CSV, PDF via USB, Ethernet, or Wi-Fi.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 8 kW.
· Control Voltage: 24V DC for auxiliary systems.
Safety Features
· Emergency Stop: Strategically placed buttons on the front and rear panels.
· Overload Protection: Real-time monitoring of force during case insertion and cap welding.
· Laser Safety: Class 1 laser safety enclosure with interlock system.
· Protective Enclosure: Transparent cover with interlocks to prevent operation during maintenance.
· Error Alarms: Audible and visual alarms for misalignment, insertion failure, or welding defects.
Environment & Installation
· Operating Environment:
o Temperature: 10–35°C
o Humidity: ≤60% RH (non-condensing).
· Noise Level: ≤75 dB during operation.
· Installation Requirements:
o Flat, vibration-free surface.
o Minimum clearance: 800 mm on all sides.
Cooling System
· Type: Water-cooled laser module with independent chiller.
· Flow Rate: 10–15 L/min.
· Cooling Power: 3.5 kW.
Maintenance and Warranty
· Maintenance Schedule:
o Weekly: Clean insertion gripper, laser lens, and alignment components.
o Monthly: Inspect servo motors, pneumatic system, and cooling system.
o Quarterly: Full calibration of alignment and welding systems.
· Warranty Period:
o Standard: 12 months.
o Extended: Up to 36 months available upon request.
