PowerWeld-BB5000: High-Speed Busbar Laser Welding for EV Battery Packs

The PowerWeld-BB5000 is purpose-built for EV battery pack busbar welding, delivering 5000W of fiber laser power with oscillating beam technology. It handles both copper and aluminum busbars with minimal spatter and excellent surface finish — meeting the strict electrical conductivity requirements of high-voltage battery systems.

Key Features

• 5000W fiber laser with oscillating beam (wobble welding) for wide, uniform weld seams
• Dual-material capability: copper (up to 2mm) and aluminum (up to 3mm) busbars
• Gantry-type XY motion: 1500×800mm working area, servo-driven for ±0.03mm repeatability
• Coaxial seam tracking: compensates for busbar position variation in real time
• Integrated fume extraction: HEPA-filtered, cleanroom-compatible
• MES/SCADA interface: Ethernet, Profibus, EtherCAT supported

Technical Specifications

Applications

Ideal for PACK-level busbar welding in passenger EV, commercial EV, and grid-scale ESS production. Supports both manual loading and full automation integration with robotic arms and conveyor systems.

Oscillating Beam Advantage

Conventional laser welding on copper produces keyhole instability and spatter. The BB5000's oscillating beam distributes energy evenly across the weld pool, suppressing porosity and achieving electrical resistance at the weld joint below 0.1mΩ — essential for high-current busbar connections.