In today’s rapid development of AI, data centers, new energy vehicles, battery packs, and energy storage stations, copper-aluminum bars have replaced high-voltage wiring harnesses as essential components for circuit connections.
Copper and aluminum discharges are responsible for large current conduction and high-voltage connectivity, and quality and efficiency directly determine the safety and cost of the entire equipment.
Using traditional processes, the hard casting of copper and aluminum is all manual, and the processing is slow and tiring, and consistency is not easy to ensure. With the progress of technology , copper and aluminum hard row processing is becoming more and more automated, automatic production line also came into being.
Traditional copper and aluminum hard disc processing
Traditional copper and aluminum hard disc processing is basically manually processed:
Bend first → Artificial laser stroke → Manual skin peeling → Glue cleaning → Final perforation
The product morphology also needs to be increased in assembly and commissioning, and the equipment occupies a lot of space, is low in efficiency, and the quality is unstable.
A fully automatic production line for aluminum columns
The automatic aluminum disc production line mainly includes straight strip laying, strip processing, stamping, bending, testing, packaging and other processes. The complete process diagram is as follows:
Rolling ingredients: After placing the aluminum band roll on the rack, it is automatically conveyed without a human being to move it.
Flatten the school directly: The flattening machine presses the roll band straight to ensure the accuracy of the subsequent machining.
Servo Shipment + Online Testing: Accurate delivery, and online inspection of width and thickness, and direct warning of non- conforming items.
Laser coding: The laser automatically stamps the model, batch, QR code and other trace information on the insulation layer.
Straight lines: Cut precisely according to length to make a standard straight strip.
Laser Linear Positioning: The machine automatically finds the location of the skin graft and uses a laser to draw it.
High frequency heating automatic skin peeling: Heat softens the insulation layer and the mechanical clamp tears off the outer skin.
Automatic polishing: Polish the surface of the stripped aluminum plates.
Dry Ice Cleaning: Wash residues and water stains during processing so as not to damage the material.
Ultrasonic Automatic Welding: Automatic copper rings and ultrasound precision welding.
Automatic punching + reverse angle: Make holes, remove thorns and invert corners as required by the drawings.
Completely automatic bend: Import 3D drawing, machine automatically bending.
Full size inspection: Testing instruments + automatic testing, and qualifications are required for clearance.
Automatic packaging: Finished products are covered with film , packed and labeled , and directly delivered to the warehouse.
The advantages of straight bar automation process
- Fewer people: One line from 30 people to just 1-2 people to watch.
- Faster speed: copper bar from 160 seconds to just 40 seconds.
- Aluminum bar more efficient: from 320 seconds to 95 seconds , efficiency increased by more than 2 times.
- Change faster: Change the product from 30 minutes to 15 minutes.
- More stable quality: uniform size , no human error , reach automotive grade standard.
- Lower cost: Fewer fixtures , less space , simple maintenance , more economical in the long run.
Contact Semco Infratech to discuss your EV & BESS manufacturing requirements and discover how automatic assembly solutions can enhance your production efficiency, ensure product quality, and accelerate your path to market competitiveness.