As a core piece of equipment in modern battery manufacturing, the fully automated high-speed battery pack welding machine requires comprehensive safety protection covering the entire process, including electrical, mechanical, environmental, and operational aspects, to ensure personnel safety, equipment stability, and product quality.
Electrical safety is fundamental. The welding machine involves high-voltage electricity and high current, necessitating reliable grounding to connect the equipment's metal casing to the earth and prevent electric shock accidents caused by leakage. Simultaneously, a leakage current protection device must be installed to monitor the residual current in the circuit in real time, and the power supply must be quickly cut off when the leakage current exceeds the limit. Furthermore, electrical wiring must be wrapped with insulating materials, and cables must be regularly inspected for damage or aging, especially in humid environments where moisture-proofing is crucial to prevent short circuits caused by decreased insulation performance.
Mechanical safety protection must eliminate physical risks. During welding, moving parts such as robot arms and conveyor belts may cause pinching or collisions. Safety light curtains must be installed in hazardous areas, automatically triggering a shutdown when personnel approach; protective doors must be interlocked with the equipment, stopping operation immediately upon opening the door. Mechanical limit devices prevent components from exceeding their safe travel range, while buffers absorb accidental impact energy. For high-speed welding heads, a safe movement range must be programmed to avoid contact with workpieces or personnel.
Heat source and fire protection must address the risk of high temperatures. Laser welding, resistance welding, and other processes generate high temperatures, which may cause thermal runaway or fire in battery packs. A temperature monitoring system is required to monitor the temperature of the welding area and module stacking area in real time, immediately alarming and shutting down the machine in case of abnormalities. Fume purification devices can reduce the accumulation of combustible particles. Fire extinguishing nozzles linked to smoke detectors can automatically spray extinguishing agents in the initial stages of a fire. High-risk work areas must be separated by fireproof partitions, and critical components must be wrapped with flame-retardant materials to reduce the risk of fire spread.
Environmental safety protection requires controlling working conditions. Welding fumes contain metal particles and harmful gases; local exhaust ventilation devices must capture pollution sources, and a comprehensive ventilation system must maintain air circulation. Regarding light radiation, operators must wear protective masks with matching filter numbers to prevent ultraviolet rays from burning the skin or causing photokeratitis. Shielding screens should be installed around the equipment to reduce the radiation impact of arc light on other personnel. In addition, the work area must be kept dry and dust-free to prevent electrical malfunctions caused by moisture or explosions caused by dust.
Program safety design must prevent logical errors. Welding robot programs must have built-in safety logic, such as limiting the range of motion through safety zones to prevent collisions with surrounding equipment. Fault handling programs must have automatic shutdown and alarm functions; when sensors detect abnormal pressure, current, or positional deviation, operation should be immediately stopped and maintenance personnel notified. Simultaneously, the program must be updated regularly to adapt to new processes to prevent safety accidents caused by logical loopholes.
Operator training must strengthen safety awareness. Operators must pass professional assessments and be familiar with equipment structure, process parameters, and emergency procedures. Training content covers the use of protective equipment, such as safety glasses, gloves, and flame-retardant clothing, as well as the operation of safety devices such as emergency stop buttons and fire extinguishers. Daily operations must strictly adhere to procedures; unauthorized modification of parameters or removal of protective devices is prohibited. Companies should regularly organize safety drills to improve personnel's ability to respond to emergencies.
Environmental monitoring and maintenance must ensure long-term safety. The equipment must be equipped with a gas leak detection device to prevent explosions caused by the accumulation of inert gases or oxidizers. The ventilation system must be linked to the gas concentration and automatically adjust the air exchange frequency. Routine maintenance includes cleaning welding slag, inspecting the cooling system, and calibrating sensors to ensure the equipment is in optimal condition. When the equipment is to be out of service for an extended period, rust-preventive oil should be applied to moving parts, and the control box should be powered on to remove moisture to prevent damage to electrical components.
Safety protection for a fully automated high-speed battery pack welding machine is a systematic project that requires the implementation of various measures throughout its entire lifecycle, from design and use to maintenance. By constructing a multi-layered protection system, not only can the risk of accidents be reduced, but equipment operating efficiency and product quality can also be improved, providing a solid guarantee for safe production in the battery manufacturing industry.
