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Innovation Advances Ultrasonic Metal Welding Of Large EV Battery Cables

Innovation Advances Ultrasonic Metal Welding Of Large EV Battery Cables

Craig Birrittella, Business Development Manager, Automotive, Branson Welding and Assembly at Emerson takes APMEN through its journey of enhancing welders.

The amount of time required to charge electric vehicle (EV) batteries — compared to the quick fill-ups available to gas or diesel-powered vehicles — are a significant drawback to their acceptance. In their desire to overcome this obstacle, OEMs have attempted to deploy much faster charging systems that have peak charging power of 250kW or more.

While these charging systems need only about 20 minutes to produce enough charging capacity for roughly 160 miles of driving range (depending on the car or truck), they also create a variety of problems.

To improve charging speed and capacity, EV batteries need higher-capacity wire harnesses and much thicker power cables. Today, typical EV batteries and charging stations use copper cabling of up to 95 mm2, but to satisfy the demand for faster charging speed, these cables will likely soon exceed 120 mm2.

In fact, until just recently, manufacturers currently have problems welding cables over 60 mm2, let alone the 90 mm2 or the 120 mm2 cables needed today. The problems are caused by the increased power and amplitude requirements needed to weld the thicker charging cables.


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