In the battery pack manufacturing industry, the use of resistance battery welders for electrical connectivity and battery pack assembly dates back many decades. The weld controls that provided the foundation for this market were Capacitive Discharge (CD) and AC Welders. This technology remained largely unchanged for many years and provided adequate weld quality for mainstream battery welding applications. Recent global growth in both demand and diversity of battery welders, with increasing emphasis on production quality is driving the replacement of CD and AC resistance welding power supplies in battery manufacturing with the latest inverter and linear DC power supplies.

This article addresses the benefits of using battery welders with newer technologies such as: closed-loop feedback, fast rise times, 0.1 millisecond pulse adjustments, weld monitoring with limit setting, plus a number of process tools.