Currently, the new energy vehicle market is booming, and battery technology is evolving rapidly. To meet the range and performance requirements of different vehicle models, the size, shape, and internal structure of power battery packs are showing a significant trend of diversification. For battery manufacturers and automakers, while this trend brings product flexibility, it also presents a real challenge on the production line: how to ensure that welding equipment keeps pace with the rapid iteration of products?
Traditional dedicated welding fixtures often “only work with one type of battery pack,” facing difficulties in adjustment or even complete obsolescence once the size or model of the battery pack changes. This not only leads to high repetitive investment but also severely hinders production efficiency and market responsiveness due to frequent production line switching and debugging. Addressing this industry pain point, Guheng Energy, based on its deep understanding of the new energy industry chain, has launched a flexible welding solution centered on gantry laser welding equipment, aiming to solve the dilemma of “diverse sizes and difficult compatibility” with its innovative “one machine, multiple functions” design.
Industry Challenges: The Pain of Compatibility Amidst Size Diversity
Accelerated Product Iteration Leaves Dedicated Tooling in a Passive Position
From compact sedans to full-size SUVs, from passenger cars to commercial vehicles, different platforms impose drastically different requirements on battery pack capacity and dimensions (length, width, height). Battery manufacturers and PACK companies may need to handle dozens of battery pack specifications. Traditional fixed or limitedly adjustable welding workstations often fall short when facing this flexible production demand of “small batches, multiple varieties.” Each product changeover can mean lengthy tooling design, manufacturing, and debugging cycles, as well as significant losses due to production line downtime.
The Cost Black Hole of Insufficient Compatibility
The costs of compatibility issues go far beyond the explicit investment in new equipment. The implicit costs are even more staggering: production line switchover-induced capacity downtime, low equipment utilization, the risk of re-verifying process parameters, and increasingly complex on-site equipment management. These factors combined severely weaken a company’s cost control capabilities and market competitiveness.
Guheng Solutions: The “Wide Adaptability” Approach to Gantry Laser Welding
Addressing the aforementioned pain points, Guheng Energy’s core design philosophy lies in maximizing compatibility with future changes through hardware saturation and software intelligence, building flexible production capabilities for customers facing the unknown. Our gantry laser welding equipment is a concentrated embodiment of this philosophy.
Foundation: A Gantry Structure Combining Rigidity and Openness
The equipment adopts a classic gantry structure, which naturally possesses the advantages of an open, large-span working space. Compared to cantilever structures, the gantry frame is more rigid and has higher dynamic stability, ensuring that the laser head maintains extremely high trajectory accuracy and repeatability even when moving over an ultra-wide stroke range, laying the physical foundation for consistent welding quality. This is like a stable and spacious “stage,” providing endless possibilities for “performing” battery packs of different sizes.
Core: Ultimate Compatibility Design in Three-Dimensional Space
True wide adaptability is reflected in the specific three-dimensional dimensional inclusiveness. Guheng Energy’s gantry laser welding system is meticulously designed for this purpose:
Extra-large operating plane (2000mm x 1800mm): This size range is designed to cover the largest projected area of
Wide Z-axis adjustable range (600mm～1,100mm): This is key to achieving compatibility with different battery pack thicknesses. Differences in battery pack height mainly stem from cell height, liquid cooling systems, and upper and lower housing structures. Our equipment features a Z-axis travel adjustable range of up to 500mm, flexibly adapting to various battery pack thicknesses from flat designs to high-energy-density stacks. Combined with automatic focusing, regardless of changes in battery pack height, the laser focus remains precisely applied to the workpiece surface, ensuring stable weld penetration and quality.
Empowerment: Intelligent Software and Modular Concept
Superior hardware requires a smart “brain” to drive it. The equipment features a new intelligent operating system, offering intuitive and convenient programming. It supports saving and one-click recall of welding parameters for different products, greatly simplifying changeover processes. Simultaneously, we advocate a modular fixture design concept. The equipment itself serves as a powerful universal platform, compatible with various quickly interchangeable specialized or general-purpose fixtures. When changing products, the main tasks are switching fixtures and calling up the program, achieving hardware and software synergy, and minimizing changeover time.
Customer Value: From Equipment Investment to Productivity Investment
Choosing Guheng Energy’s gantry laser welding system brings not only performance improvements to a single piece of equipment but also a transformation in production models and investment logic.
Protecting Long-Term Investments and Mitigating Technological Risks: One piece of equipment can handle multiple product generations, significantly extending the equipment’s technological lifecycle and preventing premature obsolescence due to product iterations, minimizing fixed asset investment risks.
Enhancing Production Flexibility and Responding to Market Changes: Rapid changeover capabilities enable mixed scheduling and make-to-order production, allowing companies to respond more agilely to market demand fluctuations and seize fleeting business opportunities.
Ensuring Core Processes and Building a Solid Foundation for Safety: Stable welding quality is fundamental to the structural strength, sealing reliability, and safety of battery packs. The high rigidity and precision of the equipment, combined with its wide adaptability, ensures high-quality, low-defect welding results on various products, safeguarding the safety of end products.
Wide Range of Applications
Guheng Energy’s gantry laser welding boasts wide adaptability, making it highly effective in multiple scenarios:
- Power Battery PACK Mass Production Lines: Highly compatible with welding connecting pieces for prismatic, cylindrical, and pouch battery modules, as well as sealing welding of battery pack housings.
- Battery Repair and Remanufacturing: Its excellent compatibility also applies to battery packs with complex specifications for after-sales repair, making it a powerful tool in the battery maintenance field.
- Energy Storage Battery Box Manufacturing: Adaptable to welding needs for large energy storage battery boxes of various sizes.
R&D and Prototyping Center: During the R&D phase, battery pack designs frequently change. Using this equipment avoids the need to create expensive dedicated tooling for each prototype, accelerating the R&D process.
Conclusion
In today’s new energy industry, moving toward large-scale, flexible manufacturing, the requirements for the compatibility and flexibility of production equipment have shifted from a “bonus” to a “must-have.” Guheng Energy deeply understands this trend. Our gantry laser welding equipment is not just a welding tool, but a flexible production platform for the future. Through the stability of its gantry structure, the capacity of its large space, and the empowerment of intelligent software, it truly fulfills its promise of adapting to diverse battery pack sizes, elevating the compatibility of welding equipment to a new level.
We believe that investing in flexibility is investing in future certainty. Guheng Energy is willing to work hand in hand with industry partners, providing a series of professional and reliable battery pack repair equipment, to jointly promote the development of new energy manufacturing towards a more efficient, flexible, and sustainable direction.
FAQ
Q: What is the largest battery pack size that this equipment can weld?
A: The maximum operating surface size of the Guheng Energy gantry laser welding equipment is 2000mm (length) x 1800mm (width), and the Z-axis working range height is adjustable from 600mm to 1,100mm. Theoretically, any battery pack that can be completely placed within this space and whose height is within this range can be adapted. This covers the vast majority of power battery pack specifications on the market.
Q: What specific work is required when switching from welding one type of battery pack to another?
A: The main work is divided into two parts: firstly, in terms of hardware, switching to the fixture module adapted to the new product (if a modular design is adopted); secondly, in terms of software, retrieving the pre-set welding program and parameters for the new battery pack in the control system. The entire process can be completed very efficiently under the skilled operation of technicians, achieving the core goal of flexible production.
Q: What are the advantages of galvanometer welding compared to other methods when adapting to products of different sizes?
A: This equipment adopts the galvanometer welding mode. Its advantages lie in its extremely fast laser scanning speed. For common weld points or short weld seams with varying spacing on battery packs, the laser beam can be programmed to jump and position at high speed without moving the laser head or worktable, resulting in extremely high efficiency. When adapting to products of different sizes and weld point distributions, only the scanning pattern and path program need to be modified, without physical adjustments, making changeovers faster and more flexible.
Q: Does the equipment support customized higher-power lasers?
A: Yes. The standard configuration laser power is ≤2 KW, but Guheng Energy can provide customized options for higher-power lasers based on the customer’s specific material thickness and welding process cycle requirements to ensure that various depth welding or high-speed welding needs are met.
