Introduction

As electric vehicles continue to evolve, power battery systems are moving toward higher integration, larger modules, and stricter safety requirements. The Cell Contact System (CCS) has become an important component within battery modules and packs, providing both electrical current transmission and cell signal collection.

Because CCS assemblies directly connect multiple battery cells and electrical components, welding quality is closely related to electrical performance, thermal behavior, and long-term reliability.

Traditional joining methods such as riveting and resistance spot welding can become challenging as CCS products increase in size and design complexity. High tooling requirements, long changeover times, potential weld defects, and limited production data traceability can make these processes less suitable for flexible, high-volume manufacturing.

Laser welding offers a different approach. With concentrated energy, a small heat-affected zone, high positioning accuracy, and strong automation compatibility, laser welding can be integrated with inspection and manufacturing data systems to create a more controlled CCS production process.

Why CCS Busbar Manufacturing Needs a More Flexible Welding Process

CCS assemblies typically combine materials and structures such as nickel tabs, aluminum busbars, and insulating components. These components must be assembled and joined with consistent positioning and reliable electrical connections.

As battery designs become larger and more diversified, manufacturers increasingly need equipment that can handle:

• Large-format CCS assemblies
• Multiple product configurations
• Frequent product changes
• High welding-point counts
• Consistent weld quality
• Automated inspection
• Production data collection and traceability

A laser welding system therefore needs to do more than create a weld. It must also support production flexibility, quality control, and data management.

Key Advantages of Laser Welding for CCS Components

Stable Welding Quality

Laser welding concentrates energy into a localized area, helping control heat input and minimize the heat-affected zone.

With appropriate process parameters, laser welding can support stable joining of nickel and aluminum components. Consistent welding conditions can help reduce issues such as incomplete or inconsistent joints and improve contact resistance consistency.

For battery applications, stable electrical connections are particularly important because poor connections can contribute to localized heating and affect system reliability.

Flexible Production and Faster Changeover

Traditional processes often rely heavily on dedicated molds, dies, or tooling for individual product configurations.

Laser welding relies more on programmable motion and process parameters. When combined with flexible fixtures, this allows manufacturers to adjust welding programs and tooling for different CCS designs.

This approach can reduce the dependence on dedicated tooling and simplify product changeovers as battery specifications evolve.

Easy Integration with Automated Production Lines

Laser welding is well suited to automated production environments.

A CCS laser welding machine can be integrated with upstream assembly operations and downstream testing and inspection. Production data can also be collected through a Manufacturing Execution System (MES).

This creates a connected manufacturing process in which welding parameters, product information, inspection results, and production status can be recorded for later analysis and traceability.

Large-Format CCS Processing

Battery module designs continue to increase in size, creating demand for welding systems with larger working envelopes.

Han’s Laser CCS welding equipment can accommodate CCS assemblies up to 2,000 × 500 mm, providing the working range required for large-format battery components.

Large-format processing can also reduce the need to divide a component into multiple processing sections, helping simplify production handling.

Han’s Laser CCS Automated Laser Welding Solutions

Han’s Laser develops dedicated laser welding and inspection equipment for CCS manufacturing, combining laser processing, automated handling, quality inspection, and production data management.

Two representative equipment configurations include a fully automated CCS production line and an upper-and-lower dual-station CCS laser welder.

Fully Automated CCS Production Line

The CCS automated line integrates multiple manufacturing and inspection operations into a connected production system.

Typical processes include:

Assembly → Ultrasonic Heat Riveting → Pulse Heat Riveting → Laser Welding → Electrical & Withstand Voltage Testing → AOI Inspection → Thermal Pad Application → Unloading

The production line uses automated transfer and return conveyor systems to connect individual stations.

This configuration allows multiple processes to be coordinated within a single production line rather than operating as isolated workstations.

Integrated Processing and Inspection

The line combines processing and inspection functions to reduce manual intervention.

After welding, electrical continuity and withstand-voltage testing can evaluate the assembled product, while AOI inspection can identify visual or assembly-related defects.

This combination provides multiple quality checkpoints before the finished CCS assembly leaves the line.

MES-Based Production Data Collection

The production line is equipped with an MES system for production data collection.

Manufacturing information can be uploaded in real time, allowing production teams to monitor operating conditions and track manufacturing status.

For battery manufacturing, this type of data infrastructure provides an important foundation for production traceability and quality management.

Independent Station Control

Each station in the production line can be independently controlled.

If an individual station encounters an abnormal condition, the affected station can be addressed independently before the complete line resumes operation.

This architecture helps improve maintenance flexibility without requiring every station to operate as a single inseparable unit.

Recirculating Fixture System

The production line uses a circulating fixture system to move fixtures through the manufacturing process.

After completing a processing cycle, fixtures can return through the line for reuse, supporting continuous production and improving overall line utilization.

Large-Format Compatibility

The automated line supports CCS products up to 2,000 × 500 mm, making it suitable for large-format battery module applications.

Upper-and-Lower Dual-Station CCS Laser Welding System

For applications focused specifically on CCS nickel-tab and aluminum-busbar welding, Han’s Laser also offers an upper-and-lower dual-station laser welding configuration.

The laser welding machine can be configured with SFM200Z or WFF1000 laser sources and can use either a single galvanometer or dual-galvanometer configuration.

It supports CCS products up to 2,000 × 500 mm.

Alternating Dual-Station Design

The equipment uses upper and lower alternating workstations.

While one station is being processed, the other can be prepared for the next operation. This configuration supports continuous production while providing a large working range for oversized CCS components.

The lower section uses a modular structure, while the upper section uses a chain-based mechanism, creating a compact equipment layout.

Dual-Galvanometer Configuration

For systems equipped with two galvanometers, an interlocking anti-collision function helps prevent interference between the two processing units.

The equipment can also integrate distance measurement and MES connectivity to support positioning and production data management.

Simplified Product Changeover

The system is designed with a mature equipment architecture and a large welding area.

Because welding patterns can be adjusted through programmable parameters, product design changes can be implemented without completely redesigning the core welding system.

This provides greater flexibility for CCS products that undergo frequent design iterations.

Building a Closed-Loop CCS Manufacturing Process

For modern battery manufacturing, welding alone is only one part of quality management.

A more complete production architecture connects:

Processing → Inspection → Data Collection → Traceability

Laser welding performs the joining process, while electrical testing and AOI provide quality verification. MES then connects production and inspection information to create a more traceable manufacturing record.

This integrated approach can help manufacturers identify process deviations, analyze production conditions, and improve quality management.

Applications in EV Battery Manufacturing

CCS laser welding machines are primarily used for joining components within battery module assemblies.

Typical applications include:

• Nickel tab to aluminum busbar welding
• CCS electrical connection welding
• Battery module interconnection
• CCS assembly and inspection
• Large-format battery module production
• Automotive power management components

The combination of large working areas and automated production functions makes these systems suitable for battery manufacturers dealing with increasingly large and diversified CCS designs.

Why Laser Welding Is Becoming Important for CCS Production

The development of CCS technology is closely connected to the broader evolution of EV battery manufacturing.

As battery modules become larger and more integrated, manufacturers need production equipment that can combine:

• Large-format processing
• Flexible changeover
• Consistent welding
• Automated inspection
• MES connectivity
• End-to-end traceability

Laser welding addresses these requirements by combining precise energy delivery with programmable processing and straightforward automation integration.

More importantly, when laser welding is connected with inspection and manufacturing data systems, it becomes part of a broader quality-controlled production architecture rather than an isolated welding operation.

Conclusion

The shift toward larger, more integrated CCS assemblies is changing the requirements for battery component manufacturing. Traditional riveting and resistance welding can face limitations in tooling flexibility, changeover efficiency, and production data management.

Laser welding provides a flexible alternative by combining controlled heat input, high welding precision, programmable processing, and automation compatibility.

With solutions supporting CCS assemblies up to 2,000 × 500 mm, Han’s Laser integrates laser welding with automated inspection, testing, fixture circulation, and MES data collection to support a more connected manufacturing process.

For EV battery manufacturers, the combination of large-format processing, faster product changeover, consistent welding, and full-process traceability provides a practical foundation for scalable CCS production.

Han’s Laser provides integrated laser welding and automation solutions for CCS and EV battery manufacturing. Contact Han’s Laser to discuss your CCS welding, inspection, and production requirements.