“The Resistance Welding Troubleshooting Tool is one of the top 3 systems I have encountered in my 40+ year career.” – Art Schuneman, Helgeson
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High production rate + high yield = industrial process success. Understanding both the process requirements and production environment allows companies to optimize their production rates resulting in lower cost per part and higher profit.
Battery tab welding. Battery can welding. Battery pack assembly. For each battery application and type of battery manufactured, AMADA WELD TECH offers a production solution: resistance welding, laser welding, laser marking, laser surface cleaning or laser cutting.
We have in-depth knowledge and experience for each category and application, for example, laser welding of dissimilar metals for battery tab welding and resistance welding for tab design optimization. Our in-house application labs enable proven processes to be delivered with optimized systems.
AMADA WELD TECH has extensive experience welding and marking batteries:
(such as LiPoly)
There are many materials joining requirements in battery manufacture. Depending on the size, type, and capacity, these include both internal and tab-to-terminal connections, can and fill plug sealing, and external connections. Several joining options can be considered including ultrasonic, resistance, and laser welding. Ultrasonic welding is most often used to join the internal electrode battery materials which are typically constructed of thin foils of copper and aluminum. The remaining joins - including connections inside the can, and external terminal tab connections - are suited to both resistance and laser welding. The decision to use one technology or the other is determined both by the type of weld required and production requirements. Laser welding is the joining technology of choice for can and plug applications (seam sealing).
Resistance welding is a well-established battery spot welding technology - 40 years old - and has been used in the battery industry for almost as long. Since then, advances in battery spot welders have given users improved capabilities to control different aspects of the process. The introduction of DC inverter power supplies with closed-loop control, for example, enabled welding engineers to accommodate changes in the secondary loop to address resistance. Similarly, polarity switching for capacitive discharge power supplies to enable weld nugget balancing, as well as the addition of electrode force measurement and displacement, provides manufacturers with more tools to ensure weld quality.
A typical resistance battery spot welder setup would consist of a battery spot welder power supply like AMADA WELD TECH’s capacitive discharge spot welders paired with a Thinline weld head, or our linear dc micro spot welder paired with our new eletromagnetic low force weld head.
Laser welding was introduced to the manufacturing marketplace in the mid-1980's. As the technology has matured, and the awareness spread, laser welding has become an established process. Today, it is just another tool in the manufacturing engineer's toolbox, implemented as needed. The laser produces a high intensity beam of light that can be focused to diameters as small as 0.01″. The concentration of light energy is able to melt metals rapidly, instantaneously forming a weld nugget. The non-contact process has no consumables, provides extremely tight control over the process to size the weld nugget according to requirements, and allows for implementation methods that can be geared toward the specific manufacturing requirements. Laser welding enables joining of many materials/combinations of materials, can weld thick parts, and has no limitation on proximity of weld spots.
For more information read the Battery Industry Capabilities Brochure, Battery Welding Solutions Using Laser & Resistance Technologies, Resistance Welding Tips for Getting Better Performance and Higher Currents from Battery Packs, our Contact us for a personal consultation or free sample evalution.
Button cell - aka coin cell - batteries enable compact design in portable devices. Higher voltages are achieved by stacking the cells into a tube. Although small and inexpensive to build, the stacked button cell was somewhat unstable and fell out of favor and gave way to more conventional battery formats. Most button cells today are non-rechargeable and found in watches, hearing aids, car keys and memory backup.
The cylindrical battery cell is one of the most widely used packaging styles for batteries because it is easy to manufacture and provides good mechanical stability. The tubular cylinder can withstand high internal pressures without deforming. Cylindrical battery cans are typically made of stainless steel or aluminum with stainless steel, aluminum or copper tabs.
The pouch cell battery makes the most efficient use of space achieving 90-95 percent packaging efficiency - the highest among battery packs. Eliminating the metal enclosure reduces weight, but the cell does need support and allowance to expand in the battery compartment. Typically lithium-polymer, pouch cell batteries are used in military and automotive applications and are popular for portable applications requiring high load currents like drones and hobby gadgets.
Prismatic battery cells satisfy the demand for thinner, flat geometries. Prismatic cells make optimal use of space by layering versus traditional jelly roll style. Prismatic battery cells are predominantly found in mobile phones, tablets and low-profile laptops.
Prismatic cells are also available in large formats. Packaged in welded aluminum housings they are primarily used in hybrid and electric vehicles.
Ultracapacitors - sometimes also called supercapacitors - have a much longer life than standard batteries and can work for more than a million charge and discharge cycles. Ultracapacitors store energy in an electric field versus a chemical reaction like "normal" batteries, which enables much faster charging and discharging. They are significantly lighter in weight and usually don't contain harmful chemicals or toxic metals. In addition, ultracapacitors have very little internal resistance which allows them to work at close to 100% efficiency.
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