Method of measuring electrical resistance of joints

1. A method for measuring electrical resistance of a joint, comprising:

supplying a first electrical current between a first end of a first member of the joint and a first end of a second member of the joint;

measuring a first electrical voltage between a second end of the first member and a second end of the second member;

wherein the first end and the second end of the first member are situated on opposing sides of the joint, and the first end and the second end of the second member are situated on opposing sides of the joint

calculating a first joint resistance of the joint from the supplied first current and the measured first voltage;

comparing the calculated first joint resistance to a predetermined minimum joint resistance;

comparing the calculated first joint resistance to a predetermined maximum joint resistance, wherein the predetermined maximum joint resistance is greater than the predetermined minimum joint resistance; and

outputting a result of the comparison to a receiver, wherein the result includes:

a measurement error, if the calculated first joint resistance is below the predetermined minimum joint resistance,

a failed joint, if the calculated first joint resistance is above the predetermined maximum joint resistance, and

an acceptable joint, if the calculated first joint resistance is above the predetermined minimum joint resistance and below the predetermined maximum joint resistance.

2. The method of claim 1 , wherein the joint has a first weld nugget and the calculated first joint resistance is the resistance of the first weld nugget.

3. The method of claim 2 , wherein the first member is a bus member and the second member is a first tab of a battery, and further comprising:

supplying a second current between the first end of the bus member and a first end of a second tab, wherein the second tab is opposite the bus member from a second weld nugget;

measuring a second voltage between the second end of the bus member and a second end of the second tab, wherein the first ends of the bus member and the second tab are oriented opposite of the second weld nugget from the second ends of the bus member and the second tab;

calculating a second nugget resistance of the second weld nugget from the supplied second current and the measured second voltage;

supplying a third current between the first end of the bus member and a first end of a third tab, wherein the third tab is opposite the bus member from a third weld nugget;

measuring a third voltage between the second end of the bus member and a second end of the third tab, wherein the first ends of the bus member and the third tab are oriented opposite of the third weld nugget from the second ends of the bus member and the third tab;

calculating a third nugget resistance of the third weld nugget from the supplied third current and the measured third voltage; and

wherein the second nugget is disposed between the first nugget and the bus member and wherein the third nugget is disposed between the second nugget and the bus member, such that the first nugget, second nugget, and third nugget form a first weld stack.

4. The method of claim 3 , wherein the first current, the second current, and the third current are substantially equal.

5. The method of claim 4 , further comprising:

supplying the first current, the second current, and the third current from a total stack current, such that the sum of the first current, the second current, and the third current is equal to the total stack current;

calculating a first weld stack resistance from the supplied total stack current and the measured first voltage, wherein the first weld stack resistance is the effective resistance of the first through third tabs, the first through third weld nuggets, and the bus member.

6. The method of claim 5 , further comprising:

comparing the calculated first weld stack resistance to a predetermined minimum stack resistance;

comparing the calculated first weld stack resistance to a predetermined maximum stack resistance, wherein the predetermined maximum stack resistance is greater than the predetermined minimum stack resistance; and

outputting a result of the comparison to the receiver, wherein the result includes:

a measurement error, if the calculated first weld stack resistance is below the predetermined minimum stack resistance,

a failed weld, if the calculated first weld stack resistance is above the predetermined maximum stack resistance, and

an acceptable weld, if the calculated first weld stack resistance is above the predetermined minimum stack resistance and below the predetermined maximum stack resistance.

7. The method of claim 6 , wherein calculating the first weld stack resistance includes dividing the measured first voltage by the supplied total stack current.

8. The method of claim 7 , wherein the total stack current is generated during charging of a battery cell.

9. The method of claim 1 , wherein the joint is a mechanical joint.

10. The method of claim 9 , wherein the mechanical joint is one of a bolt, a rivet, a clinch, and a hem, and wherein the first joint resistance is the resistance of the mechanical joint.