Battery pack resistance welding technology for electric cars

9th January 2019
Alex Lynn

It has been announced that Amada Miyachi Europe is providing resistance welding equipment for LION Smart in the development of the new fast charging LIGHT Battery. The lithium-ion battery stack has been incorporated into the proof of concept for the latest model of a fully electric extended range car. 

The new proprietary battery concept features high energy density and robust safety features, with maximum operating lifetime. Designed to increase the battery’s capacity and extend the car’s driving range, the LIGHT Battery provides 100kWh of energy and gives the car a range of up to 700km (435 miles).

LION Smart, an innovative engineering service company, operates test facilities and test laboratories for electric storage devices and performs research on lithium-ion storage technology. LION Smart used a variety of Amada Miyachi Europe resistance welding equipment during the testing phase for the LIGHT Battery concept, including an FD120 spot welding head and the ISQ20 high frequency inverter spot welding power supply.

The LIGHT Battery concept has been designed for fully automated production, with what is claiming to be the smallest part count for a battery stack in the industry. Requiring no wires, it uses wireless infrared communication. Reducing overhead parts and wires and high-level functionality integration frees up installation space. This allows the cylindrical cells to have a previously unimaginable packing density, with the densest packaging of cells and modules in a given space. The battery stack’s adjustable size means it can meet the needs of every application and customer.

The LIGHT Battery also features an innovative cooling system to guarantee maximum lifetime. All cells and high current carrying parts are totally immersed in 3M-Novev liquid. The cooling-liquid surrounds the cells evenly and there is no damage to cell chemistry by the welding process used. Safety is improved through the use of sophisticated double sided fuse and immersion.

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