In demanding applications such as high-voltage wiring in new energy vehicles, quick-change interfaces in industrial robotics, and electrical signal transmission in aerospace, connector reliability is mission-critical. Traditional welding methods often fall short—struggling with precision, thermal distortion, and limited scalability. To address these challenges, Han’s Laser has introduced the Fully Automatic Laser Welding System for Rolled-Hole Connectors—an advanced solution that delivers superior precision, efficiency, and process control.
What Is a Rolled-Hole Connector?
A rolled-hole connector is a type of electrical contact formed by rolling conductive strip material into a compact, spring-loaded, multi-beam structure. It offers three major benefits: miniaturization, vibration resistance, and low electrical resistance. The rolled structure enables space-saving designs, while the multiple contact beams ensure strong and stable electrical connections—even under high-vibration or high-voltage conditions. This connector type is widely used in harsh environments that require uncompromised performance.
Application Fields
New Energy Vehicles: High-voltage battery connectors and charging interfaces
Industrial Equipment: Quick-change robotic tool interfaces for multi-media transfer
Aerospace Systems: Electrical and power transmission in robotic systems for precision operations
Welding Challenges
1.Precision Requirements
Variations in material thickness and bending radius during rolling can cause inconsistent contact pressure.
Anti-rotation keys and barb features demand tight tolerances; manual positioning is error-prone and unreliable.
Deep blind holes (≤2mm) are hard to observe, making it difficult to ensure uniform welds and leading to a high risk of weak connections.
2.Heat Distortion Risks
Copper alloys conduct heat rapidly, and blind weld zones can exceed 200°C, causing socket deformation and increased contact resistance.
3.Throughput Limitations
Semi-automated lines rely heavily on manual feeding and inspection, which limits output and consistency, especially in high-end manufacturing environments.
Key Advantages
1.360° Dynamic Welding: Complete Blind-Hole Coverage
Equipped with a high-precision vision system and rotating welding module, the laser welder achieves full-coverage blind-hole welding. Real-time seam tracking ensures consistent weld quality. The weld seam deviation is controlled to under 0.02mm—less than one-third the thickness of a human hair—effectively eliminating false welds and ensuring structural integrity even in extreme vibration environments.
2.Smart Thermal Control: Minimizing Heat Distortion
An innovative circulating water-cooling system keeps the welding zone within ±5°C, allowing thermal impact to be controlled within 0.01mm. This reduces contact resistance by up to 30% and prevents copper oxidation and deformation. As a result, the product’s service life is more than doubled.
3.Full-Process Automation: Boosting Output, Reducing Costs
From automated feeding and visual alignment to post-weld inspection and MES system integration, this system supports 24/7 operation. It can produce up to 10,000 parts per day while reducing labor costs by 70%. With a CMK ≥ 1.67 under normal conditions, product yield rates are significantly improved. The system is compatible with 90% of market terminal sizes (φ1.5–5mm), making it suitable for a wide range of applications.
Workflow Overview
1.Tail Sleeve Loading
Automatically loads tail sleeves onto the connector body, preparing for spring contact installation.
2.Spring Contact Assembly
Precisely installs the spring components to ensure reliable electrical contact.
3.Vision-Guided Alignment
Uses high-resolution machine vision to detect and align reference marks, ensuring accurate positioning.
4.Automated Laser Welding
Performs high-precision welding with full 360° coverage, even in deep blind-hole areas.
5.Real-Time Weld Inspection
Continuously monitors weld quality to detect inconsistencies or defects immediately.
6.Active Water Cooling
Maintains thermal stability during and after welding, minimizing distortion and oxidation.
7.Circularity & Dimensional Testing
Automatically checks the geometric accuracy of the connector to meet strict tolerance requirements.
8.Automated Discharge & Sorting
Transfers completed parts to the output tray, with optional sorting based on inspection results.
The laser welding machine supports complete automation with tray-based feeding, guided assembly, dual-line visual alignment, high-speed laser welding, precision cooling, and inline quality assurance. Optional features like laser marking and airtightness testing further enhance its production versatility and cost-effectiveness. This makes it especially suitable for large-scale manufacturing of high-current copper connectors such as crown springs and twisted springs.
Conclusion
Developed by Han’s Laser, the Fully Automatic Laser Welding System for Rolled-Hole Connectors provides a robust solution for industries such as new energy, rail transit, and advanced industrial equipment. With its unmatched precision, efficiency, and adaptability, it plays a vital role in driving innovation and upgrading high-end manufacturing.
If you’re ready to transform your connector production with cutting-edge laser technology, contact Han’s Laser today. Our team is ready to help you implement intelligent manufacturing solutions tailored to your industry needs.