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GM Uses Ultrasonic Welding on Cadillac ELR Battery Pack

To improves reliability, shorten production time, and reduce costs, there are nearly 200 ultrasonic between the tabs of individual cells.

Published: 04-Aug-2013

To assure a high quality battery in the Cadillac ELR Plug-in Hybrid, GM's manufacturing team is using ultrasonic welding technology to build the battery pack, and an automated computer vision system for quality checks.

For GM's next plug-in hybrid electric car, the Cadillac ELR, the company said today they're using an ultrasonic welding technique, for battery pack construction, that's commonly used in aerospace and medical device industries. The ultrasonic welding technique planned for the ELR is meant to ensure high quality, and is said to be a contributing factor to the eight-year/100,000-mile battery system warranty.

One of the advantages of ultrasonic welding is predictable quality and performance from one battery pack to the next. Battery packs are made by joining individual cells in series and parallel configuration to implement the correct voltage and amp-hours needed for the pack. To do so, the positive and negative tabs on the cells are joined together in the correct arrangement. The Cadillac ELR battery pack has close to 200 ultrasonic welds between the tabs of individual cells.

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