Solution

Email:cynthiazheng@dpxlaser.com
Address: Room 601, Building 4, Huidongsheng Industrial Park, No. 1028 Guangqiao Avenue, Yulu Community, Guangming District, Shenzhen (South Gate)

I. Project Background (Customer Pain Points)
In the production of power batteries and energy‑storage battery modules, components such as ear tabs, busbars, cell cover plates, and battery casings often feature complex, non‑standard geometries, multiple radii, and intricate weld paths. Conventional single‑axis laser welding and galvanometer‑based spot‑welding systems offer limited trajectory flexibility, making them ill‑suited for continuous multi‑curved‑surface, multi‑position welding. Moreover, these traditional systems suffer from poor inter‑axis coordination and significant positioning errors, leading to defects such as incomplete welds, weld interruptions, uneven seams, and excessive thermal distortion. In addition, they are cumbersome to retool, have limited batch throughput, and cannot seamlessly integrate with automated assembly lines. High levels of manual intervention and inconsistent yield further exacerbate these challenges, rendering them unable to meet the stringent quality‑control requirements of large‑scale, high‑precision, and highly consistent mass production in the new‑energy battery sector.
 

II. Equipment Configuration
The Horizon laser multi-axis coordinated fully automatic laser welding workstation is equipped with a multi-axis motion control system and paired with a high-precision servo motor–reducer assembly to deliver high-speed, high-torque, and smooth motion. It supports synchronized multi-axis programming, enabling seamless switching between linear, arc, and irregular complex‑trajectory welding paths. Standardized pallet‑based batch tooling is included, allowing for the simultaneous batch welding of entire workpiece trays.
 

The equipment features an open‑type IO handshake interface, enabling seamless integration with upstream and downstream automated production lines, pick‑and‑place systems, and MES platforms to achieve fully automated, unmanned processing across the entire workflow. It can be equipped with laser marking and laser cleaning modules to deliver an integrated process that combines battery welding, traceability, and pre‑process decontamination.
 

III. Core Process Performance
1. Multi-axis coordination for complex working conditions: Precise, controllable multi-axis synchronous motion seamlessly accommodates irregular lithium‑battery geometries, multiple weld points, and continuous arc‑shaped weld beads, overcoming the challenges of complex trajectory welding that conventional equipment cannot handle. The resulting welds are smooth and uniform, with no interruptions or misalignments.
 

2. High-speed, high-stability batch processing: Featuring a servo-plus-reducer drive configuration, this system delivers rapid motion, ample torque, and smooth, vibration-free operation. It maintains consistent precision even during prolonged continuous use, significantly accelerating the overall production cycle and supporting large-scale mass production.
3. Precise and controllable welding quality: The laser creates a small heat-affected zone, with no spatter or porosity; the welds are robust and highly sealed, effectively preventing issues such as cell overheating, cold solder joints, and incomplete welds, thereby ensuring the safety and stability of the battery module.
 

4. Strong automation compatibility: batch loading via material trays combined with universal I/O integration, supporting online production on automated assembly lines; quick changeovers and straightforward commissioning, with excellent versatility across various cell and module specifications.
 

IV. Practical Value and Industry Applications
Horizon’s multi‑axis laser welding solution has been deployed at scale across numerous new‑energy lithium‑ion battery manufacturers, seamlessly supporting precision welding applications in power batteries, energy‑storage batteries, 3C lithium‑ion products, and precision kitchen and bathroom hardware. It effectively enables customers to achieve full‑coverage welding for complex components, double production throughput, and a substantial reduction in defect rates, while minimizing reliance on manual labor and lowering changeover costs. By meeting the stringent quality‑control and automated mass‑production requirements of the new‑energy sector, the solution helps enterprises upgrade their welding processes toward greater intelligence, standardization, and efficiency.