Battery Terminal Weld Tensile Testing

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

Requirement

BMZ 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 MultiTest 2.5-i 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. Emperor™ 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 Emperor™ 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

• MultiTest 2.5-i tensile tester: touchscreen-controlled system with Emperor™ software
• ILC-S 1000 N load cell
• 5 kN wedge grip
• Custom insulated grip for battery cells
• OmniTest UTM with VectorPro software and ELS load cell