The Copper Flexible Busbar Welding Machine is a high-power, high-precision solid-state bonding equipment, specifically designed for demanding applications like new energy battery flexible connectors and large-cross-section copper busbar welding. It achieves atomic-level diffusion at the interface through precise thermo-pressure control, creating a monolithic joint with near 100% conductivity and strength equal to the base metal.
HFTD-200-Y Key Specifications
| Item | Specification |
|
Model
|
HFTD-200-Y |
| Rated capacity | 200 kVA |
| Rated duty cycle | 100% |
|
Input power
|
415V±10% 50HZ 3 phases
|
| Maximum welding area | 120 × 120 mm |
| Maximum stack thickness | 20 mm |
| Standard input power | 415 V ±10%, 50 Hz, 3-phase |
| Maximum short-circuit current | 42 kA |
|
Primary input current Max.
|
300A
|
|
Primary cable
|
3*50+2*16 mm2
|
|
Secondary short-circuit current Max.
|
42KA
|
|
Secondary empty voltage
|
10.4 V
|
|
Transformer insulation grade
|
Grade F
|
|
Cooling water demand
|
0.2～0.3MPa,40 micron filtration, Resistivity of 5 kΩ. cm
|
|
Cooling water flow rate
|
150 L/min,water temperature ≤30℃
|
|
Hydraulic cylinder diameter
|
Ø120*250mm
|
|
Working pressure Max.
|
100KN
|
|
Throat depth
|
320mm
|
|
Maximum welding area
|
120*120*mm,stack thickness 20mm
|
|
Working environment
|
temperature: 1～45℃ humidity: 20～80％RH
|
The maximum welding area and stack thickness are equipment reference limits. They do not mean that every 120 × 120 × 20 mm copper component can be processed with the same tooling or parameters.
Why Use a 200 KVA Hydraulic Welding Machine?
The HFTD-200-Y sits between smaller pneumatic machines and larger hydraulic copper busbar welders. It is intended for workpieces that require a larger bonding area and more stable pressure holding than a small pneumatic system can provide, but do not require a larger 350 KVA configuration.
| 120 × 120 mm Effective Welding Area |
The machine provides an effective welding area of 120 × 120 mm. This accommodates a range of medium-size copper foil terminals and allows the graphite tooling to be designed around different busbar widths and bonding lengths. The quoted welding area is the available working range, not a guarantee that every 120 × 120 mm copper stack can be welded with the same parameters. Copper grade, foil thickness, number of layers and finished terminal thickness must also be evaluated. |
| Stable Hydraulic Pressure |
The hydraulic system applies and holds pressure during heating and cooling. Stable pressure helps maintain close contact between the copper foil layers and reduces movement of the stack during the welding cycle. The pressure value is set according to the workpiece. Too little pressure can leave gaps between layers, while excessive pressure may deform the terminal or graphite tooling. |
| 200 KVA Rated Capacity |
The "200 KVA" designation refers to the rated electrical capacity of the welding power source. It does not mean that the machine produces 200 tons of mechanical pressure. The required electrical output is determined during sample testing. A larger busbar does not always require maximum output; the actual setting depends on the contact area, copper stack and heating time. |
| Custom Graphite Tooling |
The graphite blocks are made according to the customer's busbar dimensions and terminal shape. Correct tooling supports the workpiece, transfers heat to the required area and helps maintain an even terminal surface. Tooling design should be confirmed from the actual drawing or sample rather than selected only by busbar width. |
Copper diffusion soldering demonstration
Suitable Copper Flexible Busbar Applications
Battery and Energy Storage Connections
The machine can be used to bond the terminal sections of laminated copper foil connectors installed between battery modules, battery packs, busbars and power distribution components.
Low-Voltage Switchgear and Circuit Breakers
Flexible copper links are used in switchgear and circuit breakers where electrical components need a conductive connection that can accommodate movement, vibration or assembly deviation.
Transformer Flexible Connections
Transformers and related power equipment use laminated copper connectors between coils, terminals and external busbars. Hydraulic pressure helps keep a larger foil stack aligned during terminal bonding.
Power Distribution Equipment
Copper foil busbars can be used in electrical cabinets, power distribution units and other high-current equipment. The flexible section reduces mechanical stress between fixed conductive components.
Factors That Affect Copper Busbar Welding Quality
Successful copper foil welding depends on more than machine capacity. The following conditions must be considered together.
| Process factor | Why it matters | What must be checked |
| Copper surface | Oil and oxide can interfere with layer contact | Cleaning method and storage condition |
| Foil alignment | Misaligned layers can produce an uneven terminal | Stack position and edge alignment |
| Tooling contact | Uneven contact can create local overheating | Graphite flatness and installation |
| Hydraulic pressure | Pressure affects layer contact and terminal shape | Pressure setting and holding stability |
| Heat input | Insufficient heat may leave unbonded areas | Current output and heating time |
| Holding time | The terminal needs time to consolidate | Heating, holding and cooling sequence |
| Cooling condition | Unstable cooling affects continuous production | Water flow, temperature and chiller capacity |
The welding parameters should be established with the customer's actual material. Settings from one busbar design should not be copied directly to a different foil thickness or bonding area.
Why Choose Our Machine?
Problems Solved: Fatigue fracture of flexible connector welds due to battery pack vibration; thermal runaway caused by high resistance in traditional welds under high current; inability to achieve uniform and reliable connections for large components; fluctuating yield rates and difficult quality tracing.
Customer Benefits:
- Ultimate Safety: Provides vibration-proof welds for battery systems, eliminating safety incidents caused by connection failures at the root.
- Performance Leap: Superior conductivity enhances battery charge/discharge efficiency and overall energy utilization.
- Cost Efficiency & Yield: High first-pass yield rate (>99.5%) reduces rework and scrap, enabling "zero-defect" production.
- Design Freedom: Enables welding of previously "unweldable" complex or large structures, unlocking new product designs.
What will you get ?
01
1 x Flagship HFTD-200-Y Copper Diffusion Welding Machine
02
1 Set of "Process Parameter Package" & "Operation and Maintenance Manual" for your product
03
1 In-depth On-site Installation, Debugging & Operator Certification Training
04
1 Year "Full-Coverage" Warranty, with Core Components Extended to 3 Years
05
Lifetime Free Remote Diagnostics & Process Optimization Support
FAQ
Q: What is a copper flexible busbar welding machine?
A: A copper flexible busbar welding machine joins the terminal sections of stacked copper foils using controlled heat and pressure. The middle section remains flexible, while the consolidated ends can be drilled, formed or connected to electrical components.
Q: What is the effective welding area of the HFTD-200-Y?
A: The HFTD-200-Y has a 120 × 120 mm effective welding area. Actual workpiece suitability also depends on copper grade, foil thickness, number of layers, total stack thickness and the required welding cycle.
Q: Does 200 KVA mean 200 tons of welding pressure?
A: No. The 200 KVA value refers to the rated electrical capacity of the welding system. Hydraulic pressure is a separate parameter and should be selected according to the workpiece and tooling configuration.
Q: Does copper foil welding require solder or flux?
A: The standard process does not require solder or flux. The copper foil layers are consolidated through controlled resistance heating and hydraulic pressure. Surface preparation and correct parameter settings remain important.
Q: Can the machine weld tin-plated or nickel-plated copper foil?
A: Plated copper may be tested, but the coating material and thickness can affect heating and surface appearance. Samples should use the same copper and plating specification planned for production.
Wuxi Haifei Intelligent Equipment Co., Limited is one of the leading manufacturers and suppliers of Copper Flexible Busbar Welding Machine in China. With abundant experience, we warmly welcome you to buy advanced Copper Flexible Busbar Welding Machine for sale here from our factory. Quality products and reasonable price are available.
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