TWU Tab Welding Unit

Overview

Automatic system for trimming and ultrasonically welding tabs onto lithium-ion cells. The configuration includes 1 tab trimming station and 2 independent ultrasonic welding stations (one for anode, one for cathode). Welding method: ultrasonic, with separate dedicated systems for positive and negative tabs. Cells are loaded into workpiece carriers on an automatic shuttle that transfers them through the trimming and welding cycle without further operator intervention. Two automatic tab feeding systems with buffer magazine (x2) supply tabs directly to the welding stations; the buffer design enables continued operation during tab replenishment to reduce downtime. Processes conventional Li-ion, advanced chemistry, and solid state cells. Optional pre-welding functionality is available. The unit supports deployment from a single standalone machine to a fully automated line, with throughput scalable from research and development to MWh production. Ultrasonic welding creates a solid-state bond without heat, helping avoid thermal damage to electrode coating adjacent to the tab. Used in industrial battery manufacturing where consistent, low-heat tab attachment is required for lithium-ion, advanced chemistry, and solid state cells. The dual ultrasonic stations allow dedicated anode and cathode tab welding in a single automated pass following tab trimming. Applicable from pilot and research environments to high-volume MWh-scale production. Cells are introduced to carriers, then the automatic shuttle manages transfer through trimming and welding while tab magazines are replenished without stopping the machine, supporting continuous operation. Configuration choices typically align with the intended tab material and thickness, welding frequency and amplitude targets, cycle time per cell, and tooling for specific tab geometries; optional pre-welding can be incorporated when the process calls for it.