Model ZHDM40 High-Density COS Machine

The ZHDM40 high-density casting-welding machine is our latest high-density cast welder, designed for cast welding of busbars, bridge connectors and terminals for high-density batteries.

Technical Specifications

1. Production Capacity: 40–60 units/hour (1000 Ah / 2 V)
2. Pneumatic Supply: 0.1 m³/min at 0.6–0.8 MPa
3. Cooling Water: 0.5 MPa, 20 L/min
4. Power Rating: 80 kW
5. Overall Dimension (L × W × H): 5800 × 3500 × 3850 mm
6. Machine Weight: 4 T

Equipment Features

• Required Operators: 2 persons
• The main machine adopts a pneumatic intermittent rotary-lifting turntable mechanism, driving four sets of pneumatic clamps to rotate for clamping and transferring pole groups across four stations.
• The turntable lifts once for every 90° rotation and sequentially cycles through four processes: pole group loading, lug trimming, brushing and flux application, mould cast welding, and pole group unloading.
• Station 1 – Pole Group Loading: Consists of a cylinder-driven lifting pallet and pneumatic clamps. During operation, the lifting pallet cooperates with the pneumatic clamps on the turntable. Manual operation completes loading and clamping of pole groups as well as 180° fixture rotation to finish preparation for the next process.
• Station 2 – Lug Brushing and Flux Coating: Composed of a cylinder-driven lifting pallet, pneumatic clamps, reciprocating platform (bristle brush, steel wire brush and flux tank), and trimming mechanism. It aligns pole lugs first, removes oxide layers with steel wire brushes, and then evenly coats lugs with flux by flux-soaked bristle brushes. This process runs automatically.
• Station 3 – Cast Welding: Includes cylinder lifting unit, pneumatic clamps, mould, demoulding mechanism, lead melting furnace, lead pump and cooling system. The working condition of this station directly determines the quality of cast-welded pole groups. This process runs automatically.
• Station 4 – Pole Group Unloading and Jar Loading: Equipped with a cylinder-driven lifting pallet and pneumatic clamps. Fixtures that have rotated 180° return to their home position; the clamps then release, letting finished pole groups drop onto the pneumatic lifting pallet. Operators retrieve the pole groups and load them into battery jars to complete the entire welding cycle.