Manual Press Resistance Welders Copper Busbar Pneumatic Hydraulic Polymer

This Manual Press Resistance Welding Machine is an advanced system designed for high-performance diffusion welding of copper busbars, flexible connectors, and dissimilar metals. It employs a unique pneumatic-hydraulic composite boosting system as the pressure medium, combined with high-power resistance heating. Under high temperature and pressure, it induces solid-state atomic diffusion at the workpiece interface, achieving a metallurgical bond without melting. Compared to purely pneumatic systems, it delivers more stable and powerful pressure output. Compared to hydraulic systems, it offers advantages of faster response, lower noise, and longer service life. It is particularly suited for welding challenging, high-value conductive components such as copper-aluminum foil flexible connectors, copper-aluminum busbars with nickel tabs, and large-section flexible busbars used in new energy vehicle battery packs and high/low-voltage electrical apparatus. It is a core process equipment for manufacturing critical electrical connections with high conductivity, high reliability, and long service life

• Robust & Stable Gantry Frame Structure: Features an integral high-rigidity gantry frame with excellent resistance to impact, vibration, and deformation. Internal reinforcement ribs ensure frame stability during welding, providing a solid foundation for the high pressure required in diffusion welding, guaranteeing process stability and operational safety.

• Precision Pneumatic-Hydraulic Pressure System: Utilizes a pneumatic-hydraulic booster cylinder to achieve stable, hydraulic-level high pressure driven by compressed air. The independent adjustment of the pressure head's descent/ascent speed allows for gentle application and cushioned impact, reducing noise and perfectly matching the pressure profile requirements of diffusion welding.

• Precise Guidance & Repeat Positioning: The upper electrode moves vertically on high-precision linear guides, offering extremely high repeatability positioning accuracy. This fundamentally ensures the absolute accuracy and consistency of weld spot locations, which is critical for precision welding of multi-spot arrays.

• Comprehensive Electrical Safety & Insulation: The secondary circuit employs a design with an insulated pressure cylinder base and upper arm, providing reliable insulation. This allows the machine to be installed and operated directly on a metal worktable without short-circuit concerns, ensuring safety and practicality.

• High-Power, Efficient Water-Cooled Source: The main welding circuit incorporates a fully water-cooled resistance welding transformer and rectifier, delivering strong and stable power output. The efficient water-cooling system ensures sustained operational capability and energy efficiency under high-current, prolonged welding conditions.

• Efficient Human-Machine Interface & Safety Monitoring: Controlled via a foot switch for efficient and convenient operation that aligns with ergonomics. The machine is equipped with air and water pressure switches accompanied by audible/visual alarms, effectively preventing welding initiation during coolant or power medium abnormalities, providing dual protection for both equipment and operator

Electrode Selection

The upper and lower electrodes can be equipped with tungsten or graphite materials, which can meet the needs of high-temperature welding, high conductivity, and long service life.

Hydraulic Cylinders

Adopting aluminum alloy cylinder barrel, low damping sealing ring, and light friction ring combination with hydraulic cylinder, the surface is wear-resistant and has a long service life, achieving extremely high dot speed, electrode pressurization, smooth and fast.

Dual Gas Storage Tanks

Dual backup dedicated gas storage tanks, greatly reducing welding pressure fluctuations and ensuring stable welding force.

Waterway Components

All waterway components undergo surface treatment to prevent rusting, and waterway drainage is independently discharged to the water tank. Based on the outflow situation, blockages in the waterway can be observed and eliminated.

Our factory can customize according to your requirments. More details, please contact!