Copper Battery Tab Welding

As battery technology improves and the current capacity of battery packs increase, the bus bar material used in battery packs is required to be more conductive. Therefore, copper alloys are more and more commonly used for battery tabs and bus bars. The Avio High Frequency Inverter is ideal for this type of application.

This welder uses closed loop feedback to monitor and adjust the weld thousands of times per second. The constant monitoring and adjustment of the weld cycle means that slight variations in the product are mitigated and the same weld result is achieved each time.

Quality assurance is key in battery pack manufacture. Limits can also be set on this welder so that the operator or machine PLC is notified when a weld is out of assigned quality limits. Periodic testing can also be completed in order to prove the weld quality. A pull test can be completed, testing the Newton value it takes to pull the tab from the battery after welding. A good weld should also leave the weld nugget on the battery can.