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EV-Cube Battery Module Welding System

Automated Cylindrical Cell to Busbar Welding System

EV-Cube Battery Module Welding Systems are fully-automated, turnkey welding solutions with proven process capability for welding cylindrical cell battery modules. These systems can accelerate welding process development and expedite time to first production with the welding process knowledge system programming expertise and tooling design services available from IPG.

Fast, Configurable & Automated

  • FAST LASER WELDING typically 3 cells per second
  • HIGHLY CONFIGURABLE TURNKEY SYSTEM offers single vendor support with expert process development & tooling design optimized for the application requirements
  • AUTOMATED cylindrical cell battery module welding with fully integrated control software and single user interface for simple operation
 

Download EV-Cube Datasheet 

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EV-Cube welding systems, with proven battery module process capability, accelerate the time to first product with minimal laser welding experience required.

System Options for Increased Productivity

  • Largest selection of system components best suited to match application
    • Lasers including CW, QCW, Pulsed and AMB dual beam (single-mode and multi-mode options)
    • High-power welding heads including fixed beam, scanning beam and wobble welding
  • Custom-designed part tooling includes busbar clamping for optimal yield and accelerated time to first part
  • Vision alignment to increase positional accuracy for improved weld performance
  • Real-time weld measurement protects against catastrophic part failure and recalls 
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Real-Time Weld Measurement for Optimal Battery Module Production

  • Optional real-time weld depth measurement option provides 100% verification of weld depth into the Li-ion cell casing
  • Non-destructive verification of penetration depth into cell casing avoids catastrophic part failurs and recalls 
  • Ensures process compliance and notifies operator of gradual parameter degradations
  • Enables predictive preventative maintenance
  • Non-conforming parts can be re-welded to salvage the module
  • Test data recorded and available for later quality analysis
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Platform Configurations Available for Typical Battery Cell Applications

  • System components configurable for busbar welding of cylindrical, pouch, or single-sided prismatic cells
  • Easily welds copper, aluminum, nickel, stainless steel, nickel-plated steel and nickel plated copper
  • Accomodates parts up to 1,000 x 1,000 x 600 mm and weighing up to 450 kg
  • Part loading options
    • Manual part load or conveyor pass-through
    • Automated entry and exit doors
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Granite Base for High-Stability Busbar Welding

  • Provides vibration dampening and structure stiffness
  • Large thermal mass and low coefficient of thermal expansion
  • Naturally stress-relieved structure

Linear Motors for High-Accuracy & Reliability

  • Increases positioning accuracy and speed
  • Eliminates common wear issues and increases uptime
    • No gearbox to convert rotational to straight-line motion
    • No wear or degradation over time 

Accelerated Busbar Welding Process Development & Prototyping

  • Easily implemented as a turnkey system
    • Compact system with small footprint saves on floorspace
    • Accommodates all standard battery module sizes
  • Easily integrated into larger manufacturing lines
    • Standard part conveyor and MES interfaces
    • Conveyor in-feed and out-feed
  • System architecture accommodates rapidly evolving battery design and material selections
  • Highly capable to build sufficient amount of prototypes to statisfy qualfication requirements
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