The copper foil flexible connection polymer diffusion welding machine can weld workpieces with complex structures, large thickness differences, and large cross-sectional parts. It heats the entire workpiece evenly, resulting in minimal stress and deformation, ensuring the dimensional accuracy of the welded parts.
Customer Background & Pain Points
Company Q specializes in the new energy vehicle industry, primarily manufacturing flexible connection components for NEVs. Their main customers include Tesla and emerging domestic EV brands. As the NEV industry booms, Company Q’s production capacity continues to hit new highs. However, during trial production of a new product, they encountered the following issues:
- Due to a wide variety of product types, operators constantly need to adjust the position after changing graphite electrodes, which greatly increases workload.
- The existing equipment uses AC power. When multiple machines operate together, grid voltage fluctuates significantly, and energy consumption is extremely high.
- During trial production, defective products often appear because core parameters cannot be effectively controlled, resulting in unstable debugging.
- Automakers require strict quality control, meaning all relevant production data must be traceable. However, the old equipment lacks this capability.
- Company Q was very frustrated by these four problems and couldn’t find a solution.
High Customer Requirements for New Equipment
After encountering these production issues, Company Q was referred by an automaker to contact us (Anjia) in October 2023 for help. After discussing with our project engineers, they proposed the following customized requirements:
- The machine must allow quick change and adjustment of graphite electrode positions.
- The machine needs a new power supply to reduce energy consumption.
- Core parameters must be controllable to eliminate quality defects.
- The machine must have data collection capabilities and be able to transmit relevant data synchronously to the factory’s MES system.
None of the existing machines could meet these requirements. So what to do?
Developing a Copper Foil Diffusion Welding Machine Based on Customer Needs
To address all of the customer’s requirements, our R&D, welding process, and sales departments jointly held a project kickoff meeting. We discussed processes, structures, power feeding methods, testing, and control methods, identified key risks, solved each one, and finalized the basic direction and technical details as follows:
Process Confirmation: Our welding process engineers quickly adjusted the sample electrodes and used our existing diffusion welding machine for test welding. Through mutual testing, we met Company Q’s technical requirements, confirmed the welding parameters, and ultimately selected the copper foil diffusion welding machine.
Welding Solution: Our R&D and process engineers worked together to finalize the copper foil diffusion welding machine solution based on customer requirements. The machine consists of a variable-frequency inverter power supply, a hydraulic pressure mechanism, an infrared temperature measurement system, graphite electrodes, and an industrial PC (HMI).
Machine Advantages:
The machine platform includes positioning mechanisms, and graphite electrodes use a pneumatic quick-clamp mechanism for fast changeover between different sizes.
The variable-frequency inverter power supply provides three-phase balance. Power consumption is only two-thirds of the old equipment, supporting 24/7 continuous operation with over 30% energy savings.
Welding pressure, temperature, and other parameters have upper and lower limits. If limits are exceeded, the machine automatically stops and alarms, ensuring 100% welding quality.
Sensors collect relevant data. The industrial PC system automatically transmits real-time welding data to the MES system.
Delivery Time: 15 working days.
We discussed the above technical solution and details thoroughly with Company Q. Both parties reached an agreement and signed a Technical Agreement as the standard for design, manufacturing, and acceptance. In November 2023, we signed the equipment purchase contract with Company Q.
Fast Design, On-Time Delivery, and Professional After-Sales Support Earn Customer Praise!
After finalizing the technical agreement and signing the contract, our project manager immediately held a production kickoff meeting. We set timelines for mechanical design, electrical design, machining, purchased parts, assembly, and joint debugging, as well as customer pre-acceptance, rework, final inspection, and delivery. Using our ERP system, we efficiently issued work orders to all departments and tracked progress.
Time flew by. Within 15 working days, the custom copper foil diffusion welding machine for Company Q passed aging tests. After our professional after-sales engineers provided on-site installation, debugging, and technical, operational, and maintenance training for one week, the machine went into normal production and fully met the customer’s acceptance criteria. Company Q was extremely satisfied with the actual production and welding results of the copper foil diffusion welding machine. It solved their welding efficiency problems, improved product quality, reduced labor costs, and supported the implementation of a smart factory. They gave us great recognition and praise!
Satisfying Your Customization Needs is Agera’s Mission!
The customer is our teacher. What materials do you need to weld? What welding process and requirements do you have? Do you need a fully automatic, semi-automatic, or assembly line solution? Just let us know. Agera can “research, develop, and customize” for you.
Post time: Apr-09-2026
