PowerWeld-TC2000: Precision Tab Connector Laser Welding for Next-Gen EV Batteries

The PowerWeld-TC2000 is a dedicated 2000W laser welding system engineered for EV battery tab-to-busbar and tab-to-cell connector welding. Designed for high-volume production lines, it delivers repeatable, spatter-free welds on ultra-thin copper and aluminum tabs — critical for battery pack reliability and longevity.

Key Challenges Solved

• Thin-tab distortion: Proprietary beam shaping minimizes heat input, preventing deformation on 0.1–0.3mm foil tabs
• Dissimilar material joining: Optimized pulse waveform for Cu-Al and Cu-Ni tab combinations without intermetallic cracking
• High-speed throughput: Up to 120 cells/min with inline vision alignment, meeting Tier-1 OEM cycle time requirements

Technical Specifications

Why PowerWeld-TC2000?

• Zero spatter — clean welds protect adjacent cells from contamination
• Real-time weld monitoring — inline photodiode + CCD inspection, auto-reject on defect
• Flexible fixture system — quick-change tooling for multi-format production
• CE and UL certified — meets global EV manufacturing safety standards
• Remote diagnostics — 24/7 support via secure cloud connection

Applications

Ideal for prismatic cell module assembly, pouch cell stacking lines, and cylindrical cell pack integration in passenger EVs, commercial vehicles, and energy storage systems (ESS).

Request a weld sample or line integration consultation — our application engineers respond within 24 hours.