Battery terminal weld integrity tensile test

16 May 2019
Mecmesin
www.mecmesin.com/publications/battery-terminal-w...

BMZ is one the largest European suppliers involved in the design and manufacture of specialist custom made battery systems for mobile power applications.

As part of their production process, BMZ Poland in Gliwice needed to test the integrity of the welding on electrical connections fixed to each end of one of their rechargeable cells. Each connection is welded in two places, and BMZ needed to know that both welds have been made correctly. The tests needed to be made on the shop floor close to the production area.

Solution

ITA, Mecmesin’s distributor in Poland, supplied a MultiTest 2.5-i computer controlled test stand fitted with a 1000 N loadcell, a standard 5 kN Wedge Grip, and a custom made Insulated Grip to hold BMZ’s rechargeable cells. The MultiTest 2.5-i stand is supplied with Mecmesin’s powerful force testing Emperor™ software which is used to create the test program and collect and present the results.

An important point for BMZ was the requirement to see a graph of the results to check on the behaviour of the welds. Emperor can show a real-time graph of the test as it proceeds and reports can be written with, if required, colour coded ‘Pass’ or ‘Fail’ statements making interpreting the results extremely simple.

BMZ needed to know that the cell connections had been correctly welded in two places, so after clamping the cell body in the customised Insulated Grip, the cell connection is secured in the jaws of the 5 kN Wedge Grip. An Emperor program was written to include on-screen messages prompting the operator to load the sample correctly, run the test, and prepare for the next sample.

Emperor software controls the stand, moving the crosshead slowly at first to find a ‘Touch-on’ point as a reference so that each sample will be measured from the same starting position. After zeroing the graph, the crosshead is the moved upwards at a speed of 1000 mm per minute, subjecting the cell connection to a tensile force, breaking first one weld then the second. Emperor software calculates the peak force detected for both welds, and can save the results and create printable reports.

Test equipment

MultiTest 2.5-i supplied with Emperor software
ILC-S 1000 N Loadcell
5 kN wedge grip
Custom-made insulated grip

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Bianka Cramblit
Product Info
English
Created 16 May 2019
Modified 24 Mar 2021
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Battery terminal weld integrity tensile test

Solution

Test equipment

See also

Fast food tray crush testing

Top-load testing of plant-based PLA material bottles

Tensile testing wire joining systems

Extreme sports waterproof bio-textile mechanical properties

Automated syringe break-loose and glide force system

Edge Crush Test (ECT) of corrugated cardboard

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PET Screen Protector Release Liner Peel Testing

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