The HFVD-200-QY aluminum busbar welding machine is designed for laminated flexible connectors made from 6-series aluminum strips, hard aluminum plates and nickel sheets. Two controllers and two transformers regulate the upper and lower graphite molds independently, helping reduce temperature differences when welding wide or thick aluminum stacks.
The machine supports a maximum welding area of 90 × 60 mm, finished product thicknesses from 3.5 to 20 mm and a maximum welding pressure of 10 tons. Temperature, pressure and welding time can be stored for process review and production traceability.
Send us your busbar drawing, material grade, layer thickness and production requirement for a sample welding evaluation.
Main Technical Specifications
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Item
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Specification
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Structure
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C-type welding worktable (pneumatic-hydraulic booster cylinder)
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Control Method
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Inverter-based control with Haifei dual-power aluminum welding control system
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Temperature Measurement
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Range: 300–1200 °C; repeatability: ±0.5% TH;temperature setting & display available on the touch screen
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Operating Ambient Temperature
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5–45 °C
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Pressurization Method
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Max. output pressure: 10 T; initial pressure: 0.5 T
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Worktable Travel
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150 mm; press head positioning repeatability: ±0.05 mm
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Electrode Mounting Area
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130 mm × 80 mm
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Single Welding Area
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90 mm × 60 mm (smaller area enables faster welding)
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Applicable Welding Materials
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Hard aluminum plate + nickel sheet + multilayer aluminum strips (stacked welding)
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Material Thickness Range
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0.2–5 mm
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Product Thickness Range
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3.5–20 mm
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Welding Control Functions
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1. Output frequency: 15–22 kHz, fully digital electromagnetic induction heating power supply;
2. Dual-power control - independent constant-temperature control of the upper and lower graphite molds for higher accuracy;
3. Process-type PID closed-loop temperature control with automatic PID parameter tuning;
4. Three-stage heating: primary, secondary and tertiary heating, followed by pressure holding and natural cooling;
5. Programmable I/O outputs: 3 programmable output stages for better integration with PLC, robots, etc.;
6. Weld spot counting function.
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Protection Functions
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Automatic shut-down with alarm for abnormal water flow, current, or pressure
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Data Storage
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Production data (pressure, temperature, time, etc.) stored in database; readable, traceable, and capable of MES system integration
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Overall Dimensions (L×W×H)
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1249 mm × 1207 mm × 2157 mm (subject to the actual machine size)
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Aluminum Busbar Diffusion Welding for Flexible Connectors
The HFVD-200-QY is used to join stacked aluminum strips with solid terminal plates under controlled heat and pressure. It is suitable for aluminum flexible busbars, laminated aluminum connectors, expansion joints and conductive connections used in energy storage systems and low-voltage electrical equipment.
Unlike conventional fusion welding, the process does not require filler metal. The aluminum layers are held in a graphite fixture, heated according to a programmed temperature cycle and pressed together during the bonding stage.
The final welding program is set according to the aluminum grade, number of layers, foil thickness, terminal structure and joint area. For this reason, sample testing is recommended before the equipment and tooling are finalized.
Main Product Features
Independent Upper and Lower Heating
Two controllers and two transformers supply the upper and lower graphite molds separately. This helps reduce temperature differences across the joint.
Three-Stage Temperature Program
The controller supports three programmable heating stages with PID closed-loop temperature control. Heating, temperature holding and pressure holding can be adjusted for each product.
Stable Welding Pressure
A pneumatic-hydraulic booster cylinder provides up to 10 tons of pressure. The C-type machine frame keeps the welding area open for loading and unloading.
Process Data Recording
Temperature, pressure and welding time can be stored for production review and traceability. Programmable I/O is available for PLC, automation and MES integration.
FAQ
Q: Can the machine weld 6-series aluminum busbars?
A: Yes. The HFVD-200-QY can be configured for suitable 6-series aluminum busbars. The process must be verified according to the alloy, thickness, layer count and joint design.
Q: What is the advantage of two controllers and two transformers?
A: They allow the upper and lower graphite molds to be adjusted independently. This helps balance heating when the two sides of the workpiece respond differently.
Q: Can it weld aluminum and nickel together?
A: The machine can process suitable assemblies made from hard aluminum plates, nickel sheets and multilayer aluminum strips. Sample testing is required before confirming the process.
Q: What is the maximum welding area?
A: The standard maximum single welding area is 90 × 60 mm. Larger joints require a separate technical review.
Q: Can the machine connect with an MES system?
A: Yes. Temperature, pressure and welding-time data can be recorded, and MES integration can be configured according to the required communication method.
Wuxi Haifei Intelligent Equipment Co., Limited is one of the leading manufacturers and suppliers of aluminum busbar welding machine in China. With abundant experience, we warmly welcome you to buy advanced aluminum busbar welding machine for sale here from our factory. Quality products and reasonable price are available.
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