Busbar Termination Welder for EV Battery
Busbar Termination in EV Battery Pack
Busbars are components used to distribute electrical power. In recent years, with the emergence of EVs and their high-current, high-voltage requirements, busbars are utilized to tie battery cells together and conduct the resulting high current from the battery to the power management electronics. The powertrain systems of an electric vehicle uses an electric motor and the performance of the vehicle depends on the power capacity of the battery and the managed flow of current from that battery.
Batteries for electric vehicles are manufactured by connecting several cells to a busbar to form a singular module and dozens of modules are assembled in a battery pack. Busbar termination plays an important role in providing desired thermal and electrical controls in a battery pack. If the busbar is welded improperly it can cause a fire in the battery. That is why a highly sensitive busbar welding process must be used for busbars. Ultrasonic welding for busbars is ideal due to several advantages, joining of dissimilar material with varying thickness, joining of highly conductive material, and the low thermal input during the welding process. Furthermore, TECH-SONIC’s Closed Loop Quality Control “CLQC” allows the user to change force and amplitude during weld cycle to optimize welding parameters for busbar applications.
CLC Advantages for Busbar Termination
TECH-SONIC’s patented servo control ultrasonic welding process (Multi-step process) allows the user to apply the proper amount of force and energy to the weld at the appropriate time. By being able to control these specific welding parameters, it enables the users to create precise, consistent, and repeatable welds.
Features and Benefits of Closed Loop Control Technology for Busbar Welding
- Can weld up to 6 mm thick copper and aluminum busbar
- Longer tooling life due to “patented” Servo Control Technology
- Less power / lower operational costs
- Less defects with superior quality welds
- Measurement of pre-weld and post-weld height in micron, force in 0.1N, and energy 0.1 J (CLQC)