Systems and methods of battery cell manufacturing

Abstract

A method and system for welding contacts of a plurality of battery cells are provided. The method includes performing a scan of the cell electrode contact area of ​​each of the plurality of battery cells using a detector. Based on the scan of each cell electrode contact area, determining whether one or more possible welding sites for welding are feasible for each electrode contact area. In response to determining that one or more welding sites are feasible, selecting one or more feasible welding sites from the feasible welding sites, and welding at least one of the selected welding sites using a welding machine.

Description

Technical Field

[0001] This disclosure relates to systems and methods for manufacturing and assembling battery cell arrays. Background Technology

[0002] As the use of combustion-based power sources shifts to renewable and less polluting resources such as wind, solar, and nuclear power, storing and utilizing significant levels of electrical energy becomes increasingly important. Storing energy for applications with high current / voltage demands over extended periods (e.g., powering large / heavy-duty vehicles) can utilize a large number of battery cells (e.g., thousands) that store energy within them, along with infrastructure to deliver high levels of power to their destinations.

[0003] As demands for efficiency and power in energy transfer systems increase, battery module size also increases, along with the complexity and number of electrical connection points required for battery cells. Importantly, the connections between a large number of battery cells allow for high power surges and must be manufactured consistently. Poor connection points can lead to failures, including, for example, insufficient power transfer and short circuits. A lack of consistency between connections can also result in excessive variable impedance and imbalance within multiple parallel-connected cells, leading to energy losses due to heat generated by impedance and a reduction in the overall energy capacity of the battery pack.

[0004] Such failures and reduced energy capacity directly impact the performance of battery-powered devices. This impact can be significantly detrimental in situations where high energy efficiency and power are critical for the control, long-term durability, and reliability of powered devices (e.g., battery-powered vehicles). Therefore, maintaining robustness and consistency at connection points can be a key factor in manufacturing large battery cell arrays. Furthermore, as the number of battery cells increases, maintaining consistent alignment and electrical connections across the multiple electrical contacts and terminals of the array becomes more difficult and complex.

[0005] One type of manufacturing process involves assembling "stackable" components with specific alignment features (e.g., recesses, tabs, physical locking features). As the array of components increases, controlling alignment variations and electrically connecting them can become more difficult. Some methods for connecting electrical contacts (e.g., electrode contacts and terminals) include resistance spot welding (i.e., heating the weld site by guiding current through a contact area where resistance exists) and friction lead bonding (e.g., using ultrasonic energy to generate heat and bond materials together). However, it can be difficult to accurately identify such welding techniques and adapt them to misaligned connection points. For example, spot welding may generate sufficient heat between misaligned connection points to complete the weld, but it can be difficult to assess whether the weld has adequately bonded the connection point (e.g., for handling high-power loads).

[0006] Another welding technology is laser welding, which can achieve significantly higher throughput and significantly lower costs in mass production operations compared to any of the aforementioned joining methods, both in terms of operating expenses (OPEX) and capital expenditures (CAPEX). However, laser welding is more sensitive to misalignment between the substrate and the heat sink being welded, especially in the space between them. Therefore, applying laser welding to misaligned contact areas can damage surrounding structures due to laser beam deflection or result in poor welds that will fail early in service. Therefore, the embodiments described herein provide improved systems and methods for manufacturing and assembling large-size battery cell arrays. Summary of the Invention

[0007] In one aspect of some embodiments described herein, a detector is used to scan the electrode contact areas of each cell in the battery cell array for possible soldering sites. Based on the scan of each cell, the feasibility of each possible soldering site is determined. Feasibility can be determined based on the alignment between the determined connector and cell electrode contact areas, and whether applying solder based on this alignment in each corresponding possible contact area would result in a sufficiently electrically bonded solder joint between the electrode contact areas and the connector.

[0008] Based on the determination that at least one of the possible weld sites is feasible, at least one feasible weld site is selected and welded. In some embodiments, it is determined whether the welding of the feasible weld site is successful. Using a welding plan based on the determined feasible weld sites, additional alternative feasible weld sites can be selected and welded in response to the detection of a weld failure. In some embodiments, the battery array can be realigned or discarded in response to multiple weld failures and / or a lack of multiple available feasible weld sites.

[0009] The detection of feasible weld sites can be determined by detecting light generated by a welding laser operating in low-power mode or standard visible light, which is incident on the top of one or more cell cells at an angle of approximately 10 to 45 degrees to the plane at the top of the cell. After determining feasible weld sites, the success of the weld can be analyzed using the light generated and reflected by the laser during welding. If a poor weld is detected, an alternative feasible weld site can be selected and welded. Attached Figure Description

[0010] The above and other objects and advantages of this disclosure will become apparent from the following specific embodiments taken in conjunction with the accompanying drawings, wherein similar reference characters always refer to similar parts, and wherein:

[0011] Figure 1 This is an illustrative flowchart of a process for selecting and welding electrode contact areas of a battery cell array according to some embodiments of this disclosure;

[0012] Figure 2 This is an illustrative flowchart of a process for selecting and welding electrode contact areas of a battery cell array according to some embodiments of this disclosure;

[0013] Figure 3 These are illustrative diagrams of battery cell arrays and potential welding sites according to some embodiments of this disclosure;

[0014] Figure 4A This is an illustrative diagram of an aligned battery cell contact area with defined feasible welding points according to some embodiments of this disclosure;

[0015] Figure 4B , Figure 4C and Figure 4D This is an illustrative diagram of an misaligned battery cell contact area with defined feasible welding points according to some embodiments of this disclosure;

[0016] Figure 5A This is a schematic diagram of a computing device used in a welding system according to some implementation schemes;

[0017] Figure 5B These are illustrative diagrams of laser welding systems based on some implementation schemes;

[0018] Figure 5C An exemplary block diagram of the processing, vision, and welding circuitry in a welding system according to some embodiments of the present disclosure is shown;

[0019] Figure 6 An exemplary flowchart illustrating a process for selecting and laser-welding electrode contact regions of a battery cell array according to some embodiments of the present disclosure is shown; and

[0020] Figure 7 An exemplary flowchart of a process for selecting and laser-welding electrode contact areas of a battery cell array according to some embodiments of the present disclosure is shown. Detailed Implementation

[0021] In one aspect of this disclosure, systems and methods scan the electrode contact areas of each cell in a battery cell array for potential soldering sites. Based on the scan of each cell, the feasibility of each potential soldering site is determined. Feasibility can be determined based on the alignment between the connector and the cell electrode contact areas. Based on this alignment, it is determined whether applying solder in each corresponding potential contact area will result in a sufficient electrical connection between the electrode contact areas and the connector. Identifying and selecting feasible soldering sites among the plurality of potential soldering sites allows for robust and efficient methods and systems for assembling large battery cell arrays.

[0022] Figure 1This is an exemplary flowchart illustrating a process for selecting and welding electrode contact areas of a battery cell array according to some embodiments of this disclosure. At block 110, a scan of the electrode contact area of ​​each cell in the battery cell array is performed. The scan may be performed using an optical detector. In some embodiments as described herein, the optical detector is used to receive light reflected from different portions of the electrode contact area. The reflected light may be generated in response to laser illumination of the contact area. In some embodiments, the laser illumination is generated by a welding laser operating in a low-power mode configured to avoid damaging the contact area.

[0023] At block 120, based on the scan performed at block 110, the alignment between the electrode contact areas and the connectors to which they can be soldered is determined. In some embodiments, alignment is determined by analyzing reflected light from different portions of the electrode contact areas. These different portions may include portions of the contact areas and portions of the connectors representing the alignment between solder joints. The different portions may be represented by different materials or physical properties that cause light of different intensities and / or wavelengths to be reflected and received by the detector.

[0024] At box 130, based on the determined alignment, one or more possible weld sites among a plurality of possible weld sites for each electrode contact region are determined to determine whether welding is feasible. The feasibility of a possible weld site may be determined based on a comparison of the determined alignment with deviations from the optimal alignment. For example, certain possible feasible weld sites in the contact region that deviate from the optimal alignment may be determined as infeasible based on specific vertical and / or horizontal thresholds for deviations from the optimal alignment.

[0025] At box 140, one or more of the identified feasible solder sites are selected for soldering. In some embodiments, feasible solder sites for each contact area are organized based on different contact area portions assigned to individual terminals and / or in a specific priority or preference order. For example, feasible solder sites that are more closely centered or aligned with the terminal are designated as higher preference primary solder sites. Primary solder sites are selected first for soldering, and if soldering at the higher preference / primary solder site fails, a lower preference / alternative solder site may be selected for soldering.

[0026] At box 150, one or more of the selected weld sites are welded. The selected weld sites may initially include one or more of the highest preferred / primary weld sites. In some embodiments, the weld is analyzed to determine whether the weld passes as a specific criterion for successful welding. The analysis may be based on light received at a detector during welding. For example, a certain level of light intensity and / or a lack of wavelength received during welding is used to indicate weld failure. In response to the detection of weld failure, the same or one or more additional feasible weld sites may be welded until a successful weld is detected.

[0027] Figure 2 This is an exemplary flowchart illustrating a process for selecting and welding electrode contact areas of a battery cell array according to some embodiments of this disclosure. At block 210, a detector is used to perform a scan of the electrode contact area of ​​each cell in the battery cell array. The detector may be a photodetector, such as a photodetector or a similar device that converts light energy into an electrical output. In some embodiments, the detector operates to receive light reflected from areas of the electrode contact area, including contacts and terminals for welding.

[0028] The contact area and detector can move relative to each other to detect light from different portions of the contact area. For example, as the detector receives light signals from different portions of the contact area, the actuator can incrementally move the detector over the contact area. The detected light is used to identify components of the contact area from which light is reflected, while the position of the actuator is monitored to determine the corresponding relative position of the identified area within the contact area. The reflected light may be generated in response to illumination from a predetermined light source, such as a welding laser operating in low-power mode. Identification may be based on the wavelength / intensity light reflection distribution associated with the material from which the components are manufactured. For example, in some embodiments, the contacts are made of steel or nickel-plated steel, and the terminals (e.g., foil tabs) are made of aluminum, each terminal having its corresponding profile. The relative positions of these components can be calculated by detecting a transition from one material to another (e.g., by detecting a transition from one profile to another), while the actuator moves the detector above them in predetermined increments.

[0029] At box 220, based on the scan of box 210, the alignment of the center connector and edge connector between the corresponding contact portions of each battery cell is determined. The connectors may correspond to, for example, the negative and positive terminals of the battery cell. The alignment between components is calculated using the relative positions of the connectors to the battery cell contacts and / or other portions. For example, the positions may be compared to the optimal alignment calculated from the difference between the optimal alignment and the optimal alignment (e.g., the relative X / Y coordinate offset between components).

[0030] At box 230, based on the alignment determined at box 220, possible soldering sites within the corresponding contact area are determined to be feasible or infeasible. Possible soldering sites may include multiple possible soldering sites corresponding to the contact areas of each of the center connector and the edge connector. As further discussed herein, feasibility determination may be based on the alignment between the contact area and the corresponding connector. For example, if the deviation from the optimal alignment described above exceeds a predetermined amount, some possible soldering sites may be determined to be infeasible without first rework to correct the alignment. If the deviation from the optimal alignment is within a certain threshold, some possible soldering sites may be determined to be feasible.

[0031] At box 240, welding sites for the electrode contact area identified as feasible at box 230 are added to the welding plan. If welding of the primary welding site or alternative welding sites is unsuccessful, the welding plan may include selecting a primary feasible welding site for welding and selecting alternative feasible welding sites for welding. As further described herein, the primary welding site and alternative welding sites may be determined by their location within the contact area. For example, the welding site located at the very center of the contact area may be selected as the primary welding site, and alternative welding sites may be prioritized and ordered based on their proximity to the center of the contact area.

[0032] At box 250, laser welding is performed on the main welding site added to the welding schedule at box 240. In some embodiments, feedback from the laser welding process is received during welding. The feedback may be in the form of light transmitted / reflected from and detected by the weld in response to the weld. At box 260, based on the feedback, it is determined whether the weld was successful. In some configurations of the terminal connector and battery contact portion, unsuccessful welds will be detected because the laser directly contacts the contact portion of the battery cell (e.g., due to misalignment of the terminal connector in the contact area), resulting in a significantly higher intensity of reflected visible light in, for example, the wavelength range of 600 nm to 800 nm. It should be noted that emission of 600 nm to 800 nm light will also be observed in successful welds; however, this emission will be detected at a much lower intensity because the laser is absorbed into the terminal connector more than the contact portion of the battery cell (e.g., due to the different characteristics of the terminal connector and the contact portion). In other words, successful welds will produce a lower amount of blackbody radiation compared to unsuccessful welds that completely or partially miss the terminal connector. If soldering is unsuccessful, available auxiliary / alternative solder sites can be selected at box 270 for soldering. Based on the selection, soldering is performed on one or more alternative feasible solder sites, while similar analysis is conducted to determine soldering success. In some embodiments, alternative feasible solder sites are selected and soldered until at least one successful soldering is performed on a particular terminal or no remaining available feasible solder sites are found. In some embodiments, when soldering fails, all alternative feasible solder sites in the contact area are soldered to avoid potential imbalances and inconsistent impedances in the corresponding contact area. In some embodiments, all feasible solder sites are soldered during the initial (first) pass to increase the likelihood that the array will not require additional rework.

[0033] If the weld at box 260 is successful, box 280 determines whether additional welding is required or whether the previous weld performed at boxes 250 or 270 was the final weld under the welding plan. If the final weld under the welding plan has been performed, the welding process for the welding plan ends at box 290. If additional welding is to be performed under the welding plan, the process returns to box 250 to perform the additional welding.

[0034] Figure 3This is an illustrative diagram of a battery cell array and potential soldering sites according to some embodiments of the present disclosure. The battery cell array 300 includes a segment 305 having multiple cells and corresponding electrode contact areas 310A, 310B, and 310C. Each contact area 310A, 310B, and 310C includes two electrode contacts: centrally located button-shaped contacts (“center contacts”) 320A, 330A, and 350A, and edge contacts 320B, 330B, and 350B, respectively. Contact areas 310A, 310B, and 310C also each include center terminal connectors 325A, 335A, and 355A for soldering to the respective center contacts. Edge terminal connectors 325B, 335B, and 355B are arranged for soldering to the respective edge contacts. In some embodiments, the terminal connectors are elements of a current collector assembly (CCA).

[0035] Within the site region of each contact, multiple possible soldering sites are identified as feasible or infeasible, as described herein. For contact 320A and terminal connector 325A, site region 315A includes four soldering sites identified as feasible. For contact 320B and terminal 325B, site region 315B includes three soldering sites identified as feasible. As described herein, the feasibility of possible soldering sites can be determined based on the alignment between the determined contacts and connectors. Alignment / feasibility can be based on whether the possible soldering sites between the contacts and connectors are sufficiently located in or near the central or internal overlapping area of ​​both the contacts and terminals. For example, feasible soldering sites in region 315A are in the central overlapping area of ​​contact 320A and terminal connector 325A. Similarly, feasible sites in region 325B are in the central overlapping area of ​​contact 320A and terminal connector 325A. As described herein, these sites can be determined as feasible based on alignment within a certain maximum deviation from the optimal alignment between the corresponding contacts and terminal connectors.

[0036] Within contact area 310B, contact 330A is adequately aligned with terminal 335A to determine that four possible solder sites are feasible in area 340A. For example, the relative positions between contact 330A and terminal 335A are close enough to optimal alignment that all four possible solder sites are determined to be feasible. On the other hand, contact 330B is not adequately aligned with terminal 335B, making any possible solder site feasible. The amount of overlap between contact 330B and terminal 335B is insufficient to perform adequate soldering at any possible solder site in area 340B. In some embodiments, when such misalignment is identified, as described herein, the battery array 300 may be further realigned or reworked to re-evaluate possible solder sites before soldering following successful realignment.

[0037] Within contact area 310C, the degree to which contact 350A and terminal connector 355A are misaligned with three possible soldering sites within area 360A is determined to be feasible. Compared to contact areas 310A and 310B, a insufficient amount of overlap between the corresponding contact 350A and connector 355A in area 360A makes a fourth possible soldering site feasible. Similarly, compared to contact area 310A and connector 320B, insufficient alignment / overlap between contact 350B and terminal connector 355B makes a third possible soldering site feasible within area 360B.

[0038] Figure 4A This is a schematic diagram of an aligned battery cell contact area with defined feasible welding points according to some embodiments of this disclosure. Figure 4A The battery cell contact areas include a center contact 410 and an edge contact 430 aligned for welding to connectors 415 and 440, respectively. The feasible welding points 420 are shaped in an arcuate manner, which in some embodiments represents (e.g., using a laser) the contour to which welding is applied to the welding points. Figure 4A Possible weld sites relative to Figure 3 The possible welding sites are also slender. Figure 4A The elongated solder joints reduce the likelihood that unsoldered portions of the connector (e.g., connector 415) will separate from the corresponding contact (e.g., contact 410) during subsequent manufacturing steps or during use. The elongated solder joints also reduce resistance at the joint and increase the mechanical robustness of the solder joint to long-term shock and vibration loads during use (e.g., in electric vehicle applications). The curved shape also makes the solder joint more difficult to separate from a pure peel from the top of the foil connector 415. For example, some solder joints will be in complete shear (those that appear horizontal in the images), while others will be at least curved, making it not a straight peel. There are a total of ten possible solder joints 420, 425 on contact 410. Based on the determined center alignment between the center contact 410 and connector 415, the four central solder joints 420 were identified as feasible. The six surrounding solder joints 425 were determined to be infeasible. These additional solder joints can be used to accommodate misaligned battery cell contact areas, as further described below. The advantage of the shape and pattern of the weld sites is that, regardless of misalignment, there are up to four feasible weld sites (i.e., up to four attempts to achieve a successful weld), and each weld site has approximately the same weld length. In some embodiments, the possible weld site pattern does not change between battery cells (with...). Figure 3(The possible soldering point patterns may differ), and feasible soldering points are simply selected from a single soldering point pattern. This is advantageous because, regardless of which soldering point is used, a single clamping feature accommodating all possible soldering points can be used for each battery cell. Each of the two possible soldering points 420 on the contact 430 is determined to be feasible based on the alignment between the determined edge contact 430 and the connector 440, relative to the edge connector.

[0039] Figure 4B , Figure 4C and Figure 4D This is an illustrative diagram of misaligned battery cell contact areas with defined feasible solder sites according to some embodiments of this disclosure. Based on the alignment between contact area 410 and the corresponding connector 415, and between contact area 430 and the corresponding connector 440, determining possible solder sites 420 is feasible, while determining possible solder sites 425 is not feasible. Figure 4B As shown, since the arcuate region falls outside the overlap between the contact area 410 and the connector 415, the vertical misalignment between the contact area 410 and the connector 415 renders certain possible arcuate soldering points 425 infeasible. For example, the misalignment can be determined using methods further described herein.

[0040] like Figure 4C As shown, the horizontal misalignment between contact 410 and connector 415 causes certain possible soldering sites 425 of contact 410 to be determined as infeasible. The horizontal misalignment between contact 430 and connector 440 causes one possible soldering site 425 to fall outside the overlap between contact 430 and connector 440, and is therefore determined as infeasible.

[0041] like Figure 4D As shown, with Figure 4C In contrast, the identified misalignment in the opposite horizontal direction results in certain other possible soldering sites 425 being determined as infeasible at the relatively opposite horizontal ends of contact 410. As described herein, determining alignment and feasibility can be based on scanning portions of the contacts and corresponding connectors to determine their positions relative to each other and deviations from the optimal alignment, where the optimal alignment will reflect the feasibility of the four possible soldering sites, such as... Figure 4A As shown.

[0042] Figure 5A This is an example diagram of a computing device 518 for a welding system 500 according to some implementation schemes. Figure 5B This is an illustrative diagram of a laser welding system 500 according to some implementation schemes. Figure 5CAn exemplary block diagram of the processing, vision, and welding circuitry in a welding system 500 according to some embodiments of the present disclosure is shown. In the embodiments, one or more portions or the entirety of the system 500 may be configured to implement... Figure 1 To Figure 4 and Figures 6 to 7 A system of various features, processes, and components. Despite Figures 5A to 5C A certain number of components are shown, but in various examples, system 500 may include fewer than the number of components shown and / or multiples of one or more of the components shown.

[0043] System 500 includes a scanning / welding apparatus 567 configured and arranged to scan and weld an array of battery cells 582 of a battery module 580. The scanning / welding apparatus 567 includes welding devices / circuit 570 (such as laser welding devices), as described in some embodiments herein, for performing welding along a path 572. In some embodiments, the laser may be a pulsed Nd:YAG laser or a ytterbium-doped fiber laser with wavelengths in the range of 1060 nm to 1085 nm, as is typical in dissimilar metal laser welding with applied power between 10 watts and 30 watts. The scanning / welding apparatus 567 also includes vision circuitry 575, which can be used to perform scanning of the battery cells 582 based on light reflected from the cells 582, such as along an exemplary path 574. The vision circuitry may include detectors, such as photodetectors, CCD arrays, and / or similar devices that convert light energy into electrical output. In some embodiments, the detector operates to receive light reflected from a region of the electrode contact area, said region including contacts and terminals for welding. In some embodiments, vision circuitry 575 and welding circuitry 570 are integrated such that vision circuitry 575 receives light transmission generated (e.g., reflected / transmitted from the electrode contact area) in response to incident laser emission from welding laser device / circuitry 570.

[0044] Computing device 518 is connected to welding equipment 567, which is programmable with instructions that, when executed using control circuitry 528, cause the scanning / welding process described herein to be performed fully or partially. Computing device 518 is programmable with a user interface that accepts input and commands for managing and configuring the scanning / welding process. A connection 587 between device 518 and scanning / welding equipment 500 can be via a computer network (e.g., Ethernet / wireless). In some embodiments, device 518 is directly integrated with equipment 567 (e.g., built-in). Figure 5CAs shown, control circuit 528, vision circuit 575, and welding device / circuit 570 are interconnected to perform the scanning / welding process described herein. For example, control circuit 528 can cause welding device / circuit 570 to illuminate / weld the electrode contact area and coordinate vision circuit 575 to receive simultaneous transmissions generated in response to illumination / welding, and forward the detected / received transmission data to control circuit 528 for analysis and determination of battery cell alignment.

[0045] The computing device 518 includes control circuitry 528, a display 534, and input circuitry 516. Control circuitry 528 further includes transceiver circuitry 562, storage device 538, and processing circuitry 540. In some embodiments, device 518 and other components of system 500 or external connectivity devices (e.g., servers, network devices, storage devices, and other components not shown) may be configured to implement the features and processes described herein, either individually or in combination with device 518.

[0046] As used herein, the phrases “storage device,” “electronic storage device,” or “storage device” are to be understood as meaning any device used to store electronic data, computer software, or firmware, such as random access memory, read-only memory, hard disk drive, optical disc drive, digital video disc (DVD) recorder, optical disc (CD) recorder, Blu-ray disc (BD) recorder, Blu-ray 3D disc recorder, digital video recorder (DVR, sometimes called personal video recorder, or PVR), solid-state device, quantum storage device, or any other suitable fixed or removable storage device, and / or any combination thereof. Storage device 538 can be used to store various types of welding planning data, scan data, welding feedback data, metadata, and / or other types of data. Non-volatile memory (e.g., startup routines and other instructions in startup device 518) may also be used. Cloud-based storage devices may be used to supplement or replace storage device 538. In some embodiments, control circuitry 528 executes instructions for an application stored in memory (e.g., storage device 538). Specifically, the application may instruct control circuitry 528 to perform the functions and processes described herein. In some implementations, any action performed by the control circuit 528 may be based on instructions received from the application program. For example, the application program may be implemented as software or a set of executable instructions that can be stored in the storage device 538 and executed by the control circuit 528.

[0047] The application can be implemented using any suitable architecture. For example, it can be a standalone application implemented entirely on computing device 518. In such an approach, instructions for the application are stored locally (e.g., in storage device 538), and data for use by the application is downloaded periodically (e.g., from a server, an internet resource, or using another suitable method). Control circuitry 528 can retrieve instructions for the application from storage device 538 and process these instructions to perform the functions described herein. Based on the processed instructions, control circuitry 528 can determine the type of action to be performed in response to input received from input circuitry 516 or from a communication network receiving instructions or data via transceiver circuitry 562. For example, control circuitry 528 can be implemented with respect to various embodiments (such as... Figure 1 To Figure 4 and Figures 6 to 7 (Example) Perform the steps of the process, either in whole or in part.

[0048] In a client / server-based implementation, control circuitry 528 may include communication circuitry suitable for communicating with an application server or other network or server. Instructions for performing the functions described herein may be stored on the application server. Communication circuitry may include a cable modem, an Ethernet card, or a wireless modem for communicating with other equipment or any other suitable communication circuitry. Such communication may involve the Internet or any other suitable communication network or path. For example, a remote server may store application instructions in a storage device. The remote server may use circuitry (e.g., control circuitry 528) to process the stored instructions and / or generate a display on the computer monitor of device 585. Computing device 518 may receive input from a user via input circuitry 516 and process those inputs relevant to performing the processes described herein.

[0049] It should be understood that computing device 518 is not limited to the embodiments and methods shown and described herein. In a non-limiting example, computing device 518 may be a personal computer (PC), a laptop computer, a handheld computer, a mobile phone, a smartphone, or any other device, computing apparatus, or wireless device and / or combination thereof capable of suitably operating the systems and processes.

[0050] Control circuitry 528 may be based on any suitable processing circuitry, such as processing circuitry 540. As mentioned herein, processing circuitry should be understood to mean circuitry based on one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), etc., and may include multi-core processors (e.g., dual-core, quad-core, hexa-core, or any suitable number of cores). In some embodiments, processing circuitry may be distributed across multiple independent processors, such as multiple processors of the same type (e.g., two Intel Core i9 processors) or multiple different processors (e.g., an Intel Core i7 processor and an Intel Core i9 processor). In some embodiments, control circuitry 528 is configured to implement a soldering planning and operating system or components thereof that perform various electrode contact area scanning, soldering planning, and soldering processes described and illustrated herein.

[0051] Processing circuitry 540 may receive input 504 from input circuitry 516. Processing circuitry 540 may convert or transform the received input 504, which may be in the form of user input, digital signal, or analog signal (e.g., generated from vision circuitry 575, welding apparatus / circuit 570, and / or user input device), into a digital signal. In some embodiments, input circuitry 516 performs the conversion of the received input into a digital signal for performing the processes described herein.

[0052] Transmitting user input or other input 504 to computing device 518 can be achieved using a wired connection, USB cable, Ethernet cable, etc., attached to the corresponding input port, or using a wireless connection such as Bluetooth, WIFI, WiMAX, GSM, UTMS, CDMA, TDMA, 3G, 4G, 4G LTE, or any other suitable wireless transmission protocol. Input circuitry 516 may include physical input ports, such as USB ports, Ethernet ports, or any other suitable connection for receiving data via a wired connection, or may include a wireless receiver configured to receive data via Bluetooth, WIFI, WiMAX, GSM, UTMS, CDMA, TDMA, 3G, 4G, 4G LTE, or other wireless transmission protocols.

[0053] Figure 6An exemplary flowchart of a process for selecting and laser-welding electrode contact regions of a battery cell array according to some embodiments of the present disclosure is shown. At block 610, a scan of the electrode contact region of each cell in the battery cell array is performed. The scan may be performed, for example, by utilizing a laser, a detector, and a linear actuator, as further described herein. At block 620, based on the scan of the contact regions at block 610, the alignment of the contact regions is determined and used to determine the feasibility of possible welding sites in each contact region.

[0054] At box 635, the feasibility of an allowable level of possible solder joints is calculated. In some embodiments, the allowable level is based on whether the minimum amount of the scanned contact area includes a minimum number of feasible solder joints for each of one or more electrode contact / connector pairs in the contact area. For example, if each electrode contact / connector pair does not have at least one feasible solder joint, the contact area may be determined to be insufficiently aligned.

[0055] If feasible weld sites at the permissible level are unavailable, the contact area is removed from the weld plan at box 640. Otherwise, the contact area is included in the weld plan at box 630. As discussed with respect to embodiments herein, feasible weld sites included in the weld plan may be prioritized and / or ordered as primary and alternative weld sites for welding when the weld plan is implemented.

[0056] At box 650, it is determined whether the last contact area in the array of battery cells has been scanned. If additional contact areas are to be scanned, the process returns to box 620 to scan the next contact area in the battery cell array. If all contact areas in the array designated for scanning have been scanned, it is determined at box 660 whether there are adequately aligned contact areas with feasible soldering points that allow for horizontal alignment. For example, if the number of inadequately aligned contact areas exceeds a predetermined amount, it can be determined at box 665 that the soldering process should stop, and the entire scanned cell array needs to be realigned at box 625 or must be otherwise discarded.

[0057] At box 670, welding is performed on the selected feasible welding sites based on the welding plan. During welding, the success of the corresponding weld is determined, as further described herein (e.g., using a detector and analyzing the light received in response to the weld). During the implementation of the welding plan, the information is stored in memory (e.g., in...). Figure 5AThe computing device 518 (within the storage device 538) tracks which welds are successful or unsuccessful. At box 680, it is determined whether a permissible level of weld is successful / passable. If no more than a predetermined number of successful welds are made, the process can proceed to box 625 for realigning the battery cells that were unsuccessfully welded or could not be welded at box 620 due to identified misalignment. The battery cell array can also be discarded based on a minimum amount of contact area of ​​unsuccessfully welded or misaligned cells. If the number of successful welds exceeds a minimum predetermined amount, the welding plan is determined to have been successfully implemented and the process ends at box 685.

[0058] Figure 7 An exemplary flowchart illustrating a process for selecting and laser-welding electrode contact regions of a battery cell array according to some embodiments of the present disclosure is shown. At block 710, the process of scanning and welding each battery cell in the battery cell array is performed. At block 720, a laser (e.g., [missing information]) is used for welding. Figure 5B The welding laser 570 is configured to operate in a low-power scanning mode (such as a mode configured to avoid damaging or altering the electrode contact area). At block 730, when in low-power mode, each electrode contact area within the electrode contact area is illuminated, and a detector (e.g., detector 575) receives light reflected from the contact area in response to the illumination. The laser and detector can be positioned on each contact area, such as by predetermined incremental movements of the laser / detector and / or battery cell array, as further described herein.

[0059] At box 740, based on a scan of the corresponding contact areas, the alignment of the contact elements (e.g., each electrode contact and its corresponding connector) is determined. Based on the alignment, the feasibility of possible soldering sites for the corresponding contact areas is determined. At box 750, it is further determined whether an allowed number of battery cells have a minimum number of feasible soldering sites. For example, if a predetermined number of contact areas cannot be successfully soldered due to insufficient feasible soldering sites, the soldering process can be stopped at box 760. After stopping, the battery cell array can be further realigned before performing additional soldering, or the array can otherwise be discarded.

[0060] At block 770, when the cell array includes a sufficient number of feasible weld sites, the welding laser is reconfigured from a low-power mode to a higher-power welding mode configured for welding the contact area. At block 780, welding is performed, such as at the feasible weld sites according to the welding plan.

[0061] The above embodiments of this disclosure are provided for illustrative and not limiting purposes, and this disclosure is limited only by the appended claims. Furthermore, it should be noted that the features and limitations described in any embodiment are applicable to any other embodiment herein, and flowcharts or examples associated with one embodiment may be combined with any other embodiment in a suitable manner, performed in a different order, or in parallel. Moreover, the systems and methods described herein are operable in real time. It should also be noted that the above systems and / or methods can be applied to or used according to other systems and / or methods.

Claims

1. A method for welding contacts of multiple battery cells, the method comprising: A detector is used to perform a scan of the cell electrode contact area of ​​each of the plurality of battery cells; Based on the scan of each unit electrode contact area, determine whether one or more of the multiple possible welding sites in each unit electrode contact area are feasible; as well as For each unit electrode contact area, in response to determining that one or more welding sites are feasible, at least one feasible welding site is selected and welded from the feasible welding sites.

2. The method of claim 1, wherein the feasibility of one or more soldering sites is determined based on determining the alignment between the connector and the unit electrode contact within the unit electrode contact area.

3. The method of claim 2, wherein determining the alignment is based on detecting differences in light received from the connector and the surrounding material.

4. The method of claim 3, wherein the received light is reflected in response to illumination from the laser.

5. The method of claim 4, wherein the welding is performed by the laser, wherein the laser is configured to emit light for welding at a higher power than that used to determine the alignment.

6. The method of claim 3, wherein the connector comprises an aluminum foil tab, and the surrounding material comprises coated steel unit electrode contacts on which the aluminum foil tab is positioned, and wherein the difference in light is based on the difference in light received from the foil tab and the coated steel.

7. The method of claim 3, wherein the connector comprises a current collector assembly having a first portion and a second portion, the first portion being arranged for soldering to a button-shaped portion of the unit electrode contact, and the second portion being arranged for soldering to an edge portion of the unit electrode contact, wherein at least one possible soldering point is located at the first portion, and at least one possible soldering point is located at the second portion.

8. The method of claim 7, wherein determining the feasibility of the at least one possible welding site located on the first portion and the second portion is based on the proximity of the at least one possible welding site to the centerline of the button-shaped portion or edge portion of the unit electrode contact, respectively.

9. The method of claim 2, wherein the connector is part of a common connector, and the alignment between each unit electrode contact is determined using the common connector.

10. The method according to claim 1, further comprising: After selecting and welding at least one of the feasible weld sites: Perform the realignment of the unit electrode contact area; A detector is used to perform a second scan of the cell electrode contact area of ​​at least one of the plurality of battery cells; Based on the second scan, it is determined whether one or more of the cell electrode contact regions of at least one of the plurality of battery cells are feasible; as well as For each unit electrode contact area of ​​the second scan, in response to determining that one or more welding sites are feasible, at least one feasible welding site is selected and welded.

11. The method of claim 1, wherein the detector has a first detector and a second detector, the method further comprising: For each weld, the second detector is used to determine whether the weld is passable; as well as In response to the determination that welding of the unit electrode contact area is not feasible, another feasible welding site in the unit electrode contact area is further selected and welded.

12. The method of claim 11, wherein determining whether welding is possible can be achieved by using the second detector to detect light received from the contact area in response to welding the weld site with a laser.

13. The method of claim 11, wherein the first detector and the second detector are the same detector.

14. A system for welding contacts of a plurality of battery cells, the system comprising: Welding apparatus, the welding apparatus including a welding machine; Visual circuitry, the visual circuitry including a detector; and Processing circuitry, the processing circuitry including one or more processors programmed and configured to perform the following operations: The vision circuit and detector are configured to perform a scan of the cell electrode contact area of ​​each of the plurality of battery cells; Based on the scan of each unit electrode contact area, determine whether one or more of the multiple possible welding sites in each unit electrode contact area are feasible; as well as For each unit electrode contact area, in response to determining that one or more welding sites are feasible, at least one feasible welding site is selected from the feasible welding sites and the welding circuit of the system and the welding machine are welded to the selected at least one feasible welding site.

15. The system of claim 14, wherein determining whether one or more soldering sites are feasible is based on using the scan performed by the vision circuit and detector to detect differences in light received from the connector and surrounding material within the unit electrode contact area to determine the alignment between the connector and the unit electrode contacts.

16. The system of claim 15, wherein the welding machine includes a welding laser, wherein the received light is reflected in response to illumination by the welding laser, and wherein the welding laser is configured to emit light for welding at a higher power than that used to determine the alignment.

17. The system of claim 15, wherein the connector includes a current collector assembly having a first portion and a second portion, the first portion being arranged for soldering to a button-shaped portion of the unit electrode contact, and the second portion being arranged for soldering to an edge portion of the unit electrode contact, wherein at least one possible soldering point is located at the first portion, and at least one possible soldering point is located at the second portion.

18. The system of claim 15, wherein the connector is part of a common connector, and the alignment between each unit electrode contact is determined using the common connector.

19. The system of claim 14, wherein the one or more processors are programmed and configured to perform the following operations: After selecting and welding at least one of the feasible weld sites: Perform the realignment of the unit electrode contact area; The vision circuit and detector are used to perform a second scan of the cell electrode contact area of ​​at least one of the plurality of battery cells; Based on the second scan, it is determined whether one or more of the cell electrode contact regions of at least one of the plurality of battery cells are feasible; as well as For each unit electrode contact area of ​​the second scan, in response to determining that one or more welding sites are feasible, at least one feasible welding site from the feasible welding sites of the second scan is selected, and the selected feasible welding site of the second scan is welded using the welding circuit and welding machine.

20. The system of claim 14, wherein the one or more processors are programmed and configured to perform the following operations: For each weld, the detector is used to determine whether the weld is passable; and In response to the determination that welding of the unit electrode contact area is not feasible, another feasible welding site in the unit electrode contact area is further selected and welded.

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