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Battery Terminal Weld Tensile Testing
Battery Terminal Weld Integrity
Solution
- Touchscreen-controlled tensile testing system with software interface
- Custom-engineered insulated grips to securely hold battery cells
Benefits
- Consistent and repeatable quality checks at the production line
- Immediate visual pass/fail feedback for operators
- Comprehensive data capture for analysis and reporting
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 Poland, a leading European manufacturer of specialized custom battery systems for mobile power solutions, needed a robust method to test the welds on electrical terminals at each end of their rechargeable cells. Each terminal has two weld points, both of which must be verified for structural integrity. Tests needed to be conducted on-site near the production line to enable efficient quality control and fast feedback.
Implementation
Presto Stantest provided a Zeus Ultimo 3.0 touchscreen-controlled tensile test system fitted with a 1000 N load cell, a 5 kN wedge grip, and a purpose-built insulated grip to hold the battery cells safely. Software manages the test program, records results, and generates detailed reports. Real-time graphing lets operators observe weld behavior during testing, and optional color-coded pass/fail reporting simplifies decision-making.
During the test, the battery is secured in the insulated grip, while the terminal is clamped in the wedge grip. The software prompts the operator to position the sample correctly, then moves the crosshead to establish a reference ‘touch-on’ point. Tensile force is applied at 1000 mm/min, causing the first weld to yield, followed by the second. Peak forces for both welds are recorded, with all data stored for traceability and report generation.
Test Equipment
- UTM Zeus ultimo 3.0 tensile tester: touchscreen-controlled system with software
- ILC-S 1000 N load cell
- 5 kN wedge grip
- Custom insulated grip for battery cells
- OmniTest UTM with software and ELS load cell
Test standards
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