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Case Studies / Battery Terminal Weld Integrity – Tensile Testing

Battery Terminal Weld Integrity – Tensile Testing

Battery Terminal Weld Integrity

Solution

Software-controlled touchscreen tensile test system
Custom-engineered insulated grip for battery cells
Standard 5 kN Wedge Grip for weld fixation

Benefits

Consistent, repeatable quality control at the production line
Clear pass/fail output for immediate decision-making
Comprehensive data capture for analysis, reporting, and traceability
The MultiTest 2.5-i is highly reliable and intuitive. Since installation, we have had no operational issues, and the after-sales support from ITA, Mecmesin’s Polish distributor, has been prompt and effective.” – Miroslaw Bratus, Production Purchase Coordinator, BMZ Poland Sp.z.o.o.

Battery makers have used the Presto Stantest tensile testing system to accurately test weld integrity within the battery terminal directly on the production floor with rechargeable batteries. Fast and clear pass/fail results can be achieved with custom-designed insulated grips and wedge grips for weld fixation, as operators can perform repeatable tensile tests with the touchscreen-controlled MultiTest 2.5-i system. Each force and displacement measurement is contained in the system in real-time, allowing manufacturers to ensure that the bond is strong and that the product quality is upheld prior to final assembly. Standardization of the inspection process and software control made the automated testing easier and makes production consistency traceable while supporting traceability. A steady performance and easy-to-use interface have enabled the machine to have a smooth and efficient performance daily. Manufacturers have also enjoyed reliable after-sales service along with the realistic testing of performances that beat the performance of older manual or less fancy testing systems before.

Requirement

Client, a major European company that produces custom battery systems to be used in mobile power usage, was in need of developing a process that would ensure that the welds on the power leads of its rechargeable cells are sound. All terminals are welded on two points, all of which should be certified in strength. Testing had to be performed directly on the shop floor to integrate seamlessly with the production process.

Solution

Presto Stantest worked with client via its Polish partner ITA to supply a Zeus Ultimo 3.0 computer-controlled tensile tester. The system was equipped with a 1000 N ILC-S load cell, a standard 5 kN wedge grip, and a custom insulated grip designed to hold the battery cells securely. Software was used to create automated test sequences, capture real-time force-displacement data, and generate reports, including color-coded pass/fail indicators.

During testing, the battery cell is positioned in the insulated grip, while the terminal is held in the wedge grip. The software guides the operator through the test procedure, starting with a slow approach to identify the touch-on point, then applying a tensile load at 1000 mm/min. The system sequentially tests each weld, calculating the peak force for both joints and storing results for traceability. This process ensures that each weld meets strength specifications before the cell moves to assembly.

Test Equipment

Zeus Ultimo 3.0 touchscreen tensile tester with Emperor™ software
ILC-S N cell
5 kN wedge grip
Custom insulated grip for battery cells
OmniTest UTM with software

The arrangement is a dependable, repetitive, and secure way of manufacturers to verify weld integrity on battery terminals to guarantee stable product quality at the production stage.