Battery tray welding
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The battery tray welding robot workstation is an automated, intelligent welding system specifically designed for lightweight, precision components such as power‑battery trays for new‑energy vehicles, energy‑storage battery enclosures, battery lower housings, and frame brackets. As a core safety‑bearing component in new‑energy systems, the battery tray demands exceptionally high standards for weld sealing, surface flatness, deformation control, aesthetic accuracy, and structural strength. Addressing longstanding industry challenges—such as significant thermal distortion in manual welding, low weld‑seam accuracy, inconsistent gas tightness, poor first‑pass yield, and inadequate batch‑to‑batch consistency—this workstation integrates precision robotic welding, intelligent vision‑based positioning, low‑distortion welding processes, and real‑time quality monitoring. It enables fully automated processing of battery trays, from fixture‑based positioning and automated welding to precise forming, and is widely suited to meet the needs of mass‑standardized production and precision manufacturing for battery trays used in new‑energy passenger cars, commercial vehicles, and energy‑storage applications.
The workstation features a specialized, optimized design tailored to the aluminum alloy and lightweight thin‑walled structural characteristics of battery trays, supporting critical precision processes such as aluminum tray frame assembly, bottom‑plate welding, rib reinforcement welding, mounting bracket welding, and enclosure sealing welds. Equipped with a high‑precision 3D vision positioning system and a real‑time laser weld‑seam tracking system, the equipment automatically compensates for misalignment gaps in thin‑walled components, tooling positioning errors, and minute part deformations, dynamically correcting the welding path in real time. This effectively eliminates common welding defects caused by the tendency of thin‑walled aluminum parts to shift, weld seams to drift, and gaps to become uneven. Compared with conventional welding methods, this system delivers highly precise and controllable weld paths, concentrates heat input while minimizing thermal energy, and significantly mitigates issues such as warping, edge lifting, and deformation during battery‑tray welding. As a result, it reliably ensures tray flatness, dimensional accuracy, and assembly tolerances, meeting the stringent precision‑assembly standards of the new‑energy industry.
The workstation is equipped with a high-precision six-axis industrial robot and a dedicated aluminum‑welding precision welding system, delivering smooth motion and exceptionally high repeat positioning accuracy. It is ideally suited for demanding applications such as long welds on battery trays, continuous sealing welds, tight fillet welds, and intermittent reinforcement welds. The system features an integrated process library tailored specifically for new‑energy battery trays, compatible with commonly used aluminum alloys like 6061 and 6063. It automatically selects the optimal welding current, travel speed, and oscillation parameters based on plate thickness, structural location, and required sealing grade, ensuring stable, seamless execution of precision root pass, fill, and cap welding in a single operation. The resulting welds exhibit fine, uniform bead formation with well‑defined fish‑scale patterns, free from porosity, cracks, lack of fusion, slag inclusions, and other defects. The welds demonstrate excellent gas tightness, tensile strength, and vibration resistance, fully meeting the stringent performance requirements for battery trays—waterproofing, dustproofing, compression resistance, and vibration resilience. Consequently, both the nondestructive testing pass rate and the gas‑tightness test compliance rate of the finished products have improved significantly.
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6th Floor, Workshop 3, Hongxiang Standard Factory Building, No. 2 Hongli Road, Nanning, Guangxi, China
