A welding control method and welding system for eliminating undesirable secondary ultrasound

Abstract

The application belongs to the technical field of intelligent control, and particularly relates to a welding control method for eliminating secondary ultrasonic badness, which is applied to a welding system of tabs and pole pieces, and the welding system comprises a controller and a welding device electrically connected with the controller, and the welding device comprises a welding seat and a welding head. The welding control method comprises the following steps: placing the tabs and pole pieces to be welded on the welding seat, and performing first ultrasonic welding; the controller judges whether the lifting delay time t4 of the welding head meets a set condition, if yes, secondary ultrasonic is performed, otherwise, the controller adjusts the lifting delay time t4 according to the set condition and then performs secondary ultrasonic. The welding control method provided by the application can ensure that the secondary ultrasonic does not act on welding, and increase the stability of the welding system. In addition, the application further provides a welding system with the above welding control method.

Description

Technical Field

[0001] This invention belongs to the technical field of intelligent control, specifically relating to a welding control method and welding system for eliminating secondary ultrasonic defects. Background Technology

[0002] Today, with the development of modern society and the increasing awareness of environmental protection, more and more devices are choosing lithium-ion batteries as their power source, such as mobile phones, laptops, power tools and electric vehicles, which provides a broad space for the application and development of lithium-ion batteries.

[0003] In the battery manufacturing process, the welding problem in the winding section has always been a major concern, as both incomplete and broken welds can negatively impact the quality of the battery cells. To reduce welding problems in the winding section, existing technologies employ a welding structure using a motor and cylinder. While this mechanism significantly stabilizes the welding function of the winding machine, it also allows secondary ultrasonic waves to easily interfere with the welding process, causing adverse effects. Therefore, a novel technical solution is urgently needed to address these issues. Summary of the Invention

[0004] One of the objectives of this invention is to provide a welding control method for eliminating defects caused by secondary ultrasonic waves, addressing the shortcomings of existing technologies. This method ensures that secondary ultrasonic waves do not affect the welding process by determining whether the lifting delay time of the welding head meets set conditions, thereby increasing the stability of the welding system.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A welding control method for eliminating secondary ultrasonic defects, applied to a welding system for electrode tabs and electrode sheets, the welding system including a controller and a welding device electrically connected to the controller, the welding device including a welding base and a welding head, comprising the following steps:

[0007] Step 1: Place the tabs and plates to be welded onto the welding base and perform the first ultrasonic welding.

[0008] Step 2: The controller determines whether the lifting delay time t4 of the welding head meets the set conditions. If it meets the set conditions, a second ultrasonic test is performed. Otherwise, the controller adjusts the lifting delay time t4 according to the set conditions and then performs a second ultrasonic test.

[0009] Step 3: The controller determines whether the welding joint between the tab and the electrode sheet is stuck to the welding head. If so, an alarm is triggered; otherwise, the welding is completed.

[0010] The setting conditions are determined based on the pressure holding time t1, the secondary ultrasonic delay time t2, and the welding machine cylinder recovery compression time t3.

[0011] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, in step two, the set condition is: 0ms≤(the holding pressure time t1+the secondary ultrasonic delay time t2)-(the lifting delay time t4+the welding machine cylinder recovery compression time t3)≤5ms.

[0012] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, in step two, the recovery compression time t3 of the welding cylinder is determined by the welding cylinder of the welding device. The welding cylinder has a pressing position and a disengaging position during operation. Since the deformation of the welding cylinder is caused by the pressing position of the motor, within the deformation range of the welding cylinder, when the welding head is in contact with the welding seat and the welding cylinder is in an undeformed state, the welding cylinder deforms by the same amount the motor moves downwards, exhibiting consistency and synchronicity. Similarly, during the recovery deformation process, the welding cylinder recovers deformation by the same amount the motor moves upwards, exhibiting consistency and synchronicity. The pressing position and the disengaging position are the maximum and minimum deformation points of the welding cylinder, respectively, allowing the acquisition of the recovery compression time of the welding cylinder.

[0013] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, the pressing position is set so that the welding head is pressed down to a position that matches the tab and the electrode plate.

[0014] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, the welding head moves upward at a preset speed from the lowering position until the electrode tab and the electrode plate can be pulled out under the welding seat. At this time, the position of the welding head is the disengagement position.

[0015] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, the preset speed is set to 5mm / s-80mm / s.

[0016] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, the recovery compression time t3 of the welding machine cylinder is set to the time it takes for the welding head to move from the lowered position to the detached position through multiple monitoring by the controller until a steady state is reached. This can avoid the influence of other factors and increase the accuracy of the recovery compression time t3 of the welding machine cylinder.

[0017] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, in step two, the pressure holding time t1 and the secondary ultrasonic delay time t2 are set according to preset parameters.

[0018] As an improvement to the welding control method for eliminating secondary ultrasonic defects described in this invention, the setting parameters include welding pressure, amplitude, and welding time. When the setting parameters are determined, the holding time t1 and the secondary ultrasonic delay time t2 can be directly obtained from the welding instrument settings.

[0019] A second objective of this invention is to provide a welding system having the above-mentioned welding control method for eliminating secondary ultrasonic defects, wherein the welding system includes at least the welding device and the controller connected to the welding device.

[0020] As an improvement to the welding system described in this invention, the controller includes:

[0021] The storage module is used to store the pressure holding time t1, the secondary ultrasonic delay time t2, and the welding machine cylinder recovery compression time t3;

[0022] The judgment module is used to determine whether the lifting delay time t4 meets the set range, and also to determine whether the welding joint between the tab and the electrode sheet is stuck to the welding head;

[0023] The adjustment module is used to adjust the lift-off delay time t4;

[0024] The detection module is used to detect the weld between the tab and the electrode sheet, and transmit the data back to the judgment module;

[0025] Alarm module, used for issuing alarms.

[0026] As an improvement to the welding system described in this invention, the detection module is configured as a visual inspection device. The detection module is used to take pictures according to the trigger command to generate a state feature image of the connection between the electrode tab and the electrode sheet, and send the state feature image to the judgment module.

[0027] As an improvement to the welding system described in this invention, the alarm module is at least one of an alarm light, an alarm bell, and an alarm vibrator.

[0028] As an improvement to the welding system described in this invention, the welding device includes at least the welding base, the welding head, and the welding machine cylinder. The welding base is disposed corresponding to the welding head, and the welding machine cylinder is connected to the welding head and is used to drive the welding head.

[0029] The beneficial effects of this invention are as follows:

[0030] (1) The welding control method for eliminating secondary ultrasonic defects of the present invention is applied to a welding system for electrode tabs and electrode sheets. The welding system includes a controller and a welding device electrically connected to the controller. The welding device includes a welding base and a welding head. The method includes the following steps: placing the electrode tab and electrode sheet to be welded on the welding base and performing a first ultrasonic welding; the controller determines whether the lifting delay time t4 of the welding head meets the set conditions. If it meets the set conditions, a second ultrasonic welding is performed; otherwise, the controller adjusts the lifting delay time t4 according to the set conditions before performing a second ultrasonic welding; the controller determines whether the welding joint of the electrode tab and the electrode sheet is stuck to the welding head. If so, an alarm is triggered; otherwise, the welding is completed. The present invention, by determining whether the lifting delay time t4 of the welding head meets the set conditions and adjusting the lifting delay time of the welding head according to the set conditions, can ensure that the secondary ultrasonic welding does not affect the welding and eliminate the adverse effects of the secondary ultrasonic welding.

[0031] (2) It can greatly improve the stability of welding control methods, reduce the occurrence of false welding and broken welding, and thus standardize and regulate the welding debugging in the next stage. Attached Figure Description

[0032] The features, advantages, and technical effects of exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.

[0033] Figure 1 This is a schematic flowchart of the welding control method of the present invention.

[0034] Figure 2 This is a schematic diagram of the controller in this invention.

[0035] Figure 3 This is a schematic diagram of the welding device located in the lower pressing position in this invention.

[0036] Figure 4 This is a cross-sectional schematic diagram of the welding device in the lower pressing position in this invention.

[0037] Figure 5 This is a schematic diagram of the welding device in the detached position in this invention.

[0038] Figure 6 This is a cross-sectional schematic diagram of the welding device in the detached position in this invention.

[0039] The reference numerals in the attached figures are explained as follows:

[0040] 1-Storage module; 2-Judgment module; 3-Adjustment module; 4-Detection module; 5-Alarm module;

[0041] 100-Welding base; 200-Welding head; 300-Welding machine cylinder; 301-Cylinder piston; 400-Electrode tab; 500-Electrode sheet. Detailed Implementation

[0042] The specification and claims use certain terms to refer to specific components. Those skilled in the art will understand that hardware manufacturers may use different names to refer to the same component. This specification and claims do not distinguish components based on differences in name, but rather on differences in function. The term "comprising" throughout the specification and claims is an open-ended term and should be interpreted as "comprising but not limited to." "Approximately" means that within an acceptable margin of error, those skilled in the art can solve the technical problem and substantially achieve the technical effect within a certain margin of error. Furthermore, terms such as "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0043] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "horizontal", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0044] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0045] The following is in conjunction with the appendix Figures 1-6 The present invention will be further described in detail with reference to specific embodiments, but this is not intended to limit the present invention.

[0046] Implementation Method 1

[0047] like Figure 1 As shown, a welding control method for eliminating secondary ultrasonic defects is applied to a welding system for electrode tabs and electrode sheets. The welding system includes a controller and a welding device electrically connected to the controller. The welding device includes a welding base 100 and a welding head 200, and includes the following steps:

[0048] Step 1: Place the tab 400 and electrode 500 to be welded onto the welding base 100 and perform the first ultrasonic welding.

[0049] Step 2: The controller determines whether the lifting delay time t4 of the welding head 200 meets the set conditions. If it does, a second ultrasonic test is performed. Otherwise, the controller adjusts the lifting delay time t4 according to the set conditions before performing a second ultrasonic test.

[0050] Step 3: The controller determines whether the welding joint between the tab 400 and the electrode 500 is stuck to the welding head 200. If so, an alarm is triggered; otherwise, the welding is completed.

[0051] The setting conditions are determined based on the pressure holding time t1, the secondary ultrasonic delay time t2, and the welding machine cylinder recovery compression time t3.

[0052] Preferably, in step two, the set condition is: 0ms ≤ pressure holding time t1 + secondary ultrasonic delay time t2 - lifting delay time t4 + welding machine cylinder recovery compression time t3 ≤ 5ms.

[0053] Preferably, the welding device further includes a welding cylinder 300, which contains a cylinder piston 301 to ensure normal operation. The welding cylinder 300 has a pressing position and a disengaged position during operation. Figure 3 and Figure 4 As shown, the pressing position is set so that the welding head 200 is pressed down to a position that matches the tab 400 and the electrode 500; as Figure 5 and Figure 6 As shown, the welding head 200 moves upward at a preset speed of 5mm / s-80mm / s from the lower position until the electrode tab 400 and electrode plate 500 can be pulled under the welding seat 100. At this time, the position of the welding head 200 is the disengaged position. The recovery compression time t3 of the welding machine cylinder is set to the time value of the welding head 200 from the lower position to the disengaged position by the controller through multiple monitoring until a steady state is reached. Using the steady state time value can reduce the interference of other factors and increase the accuracy of the recovery compression time t3 of the welding machine cylinder.

[0054] Preferably, the holding time t1 and the secondary ultrasonic delay time t2 can be directly obtained from the welding instrument after being set according to the parameters of welding pressure, amplitude and welding time.

[0055] To verify the accuracy of the set conditions, it was selected that all other welding factors were consistent for anode welding, with a uniform welding pressure of 0.1 MPa, amplitude of 65, and welding time of 0.15 s. Thus, the holding time t1 was 55 ms; the secondary ultrasonic delay time t2 was 100 ms; and the welding machine cylinder recovery compression time t3 was 114 ms. No adjustment was made to the lift-off delay time t4 during the welding process.

[0056] Example 1

[0057] Set the lift-off delay time t4 to 41ms and import the formula (55+100)-(114+41)=0ms.

[0058] Example 2

[0059] Set the lift-off delay time t4 to 36ms, and import the formula (55+100)-(114+36)=5ms

[0060] Example 3

[0061] Set the lift-off delay time t4 to 39ms and import the formula (55+100)-(114+39)=2ms.

[0062] Comparative Example 1

[0063] Set the lift-off delay time t4 to 42ms and import the formula (55+100)-(114+42)=-1ms.

[0064] Comparative Example 2

[0065] Set the lift-off delay time t4 to 46ms and import the formula (55+100)-(114+46)=-5ms.

[0066] Comparative Example 3

[0067] Set the lift-off delay time t4 to 51ms and import the formula (55+100)-(114+51)=-10ms.

[0068] Comparative Example 4

[0069] Set the lift-off delay time t4 to 56ms and import the formula (55+100)-(114+56)=-15ms.

[0070] Comparative Example 5

[0071] Set the lift-off delay time t4 to 35ms and import the formula (55+100)-(114+35)=6ms.

[0072] Comparative Example 6

[0073] Set the lift-off delay time t4 to 31ms and import the formula (55+100)-(114+31)=10ms.

[0074] Comparative Example 7

[0075] Set the lift-off delay time t4 to 26ms and import the formula (55+100)-(114+26)=15ms.

[0076] Comparative Example 8

[0077] Set the lift-off delay time t4 to 21ms and import the formula (55+100)-(114+21)=20ms.

[0078] The results are shown in the table below.

[0079]

[0080]

[0081] As can be seen from the table above, the parameters adjusted using the welding debugging method in this embodiment not only make it less likely to cause problems such as incomplete or broken welds, but also greatly improve the welding performance, proving the accuracy of the set conditions.

[0082] Implementation Method 2

[0083] A welding system having the welding control method in Embodiment 1, the welding system including at least a welding device and a controller connected to the welding device;

[0084] like Figure 2 As shown, the controller includes:

[0085] Storage module 1 is used to store the pressure holding time t1, the secondary ultrasonic delay time t2, and the welding machine cylinder recovery compression time t3;

[0086] Judgment module 2 is used to determine whether the lifting delay time t4 meets the set range, and also to determine whether the welding joint of the tab 400 and the electrode 500 is stuck to the welding head 200.

[0087] Adjustment module 3 is used to adjust the lift-off delay time t4;

[0088] The detection module 4 is used to detect the weld between the tab 400 and the electrode 500 and transmit the data back to the judgment module.

[0089] Alarm module 5 is used for alarm functions.

[0090] Preferably, the detection module 4 is configured as a visual detection device. The detection module 4 is used to take pictures according to the trigger command to generate a state feature image at the connection between the tab 400 and the electrode 500, and send the state feature image to the judgment module 2.

[0091] Preferably, the alarm module 5 is at least one of an alarm light, an alarm bell, and an alarm vibrator.

[0092] Preferably, the welding device includes at least a welding base 100, a welding head 200, and a welding cylinder 300. The welding base 100 is provided corresponding to the welding head 200, and the welding cylinder 300 is connected to the welding head 200 and is used to drive the welding head 200 to ensure the normal operation of the welding device.

[0093] Based on the disclosure and teachings of the foregoing specification, those skilled in the art can make changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments described above, and any obvious improvements, substitutions, or modifications made by those skilled in the art based on the present invention are within the scope of protection of the present invention. Furthermore, although some specific terms are used in this specification, these terms are only for convenience of explanation and do not constitute any limitation on the present invention.

Claims

1. A welding control method for eliminating secondary ultrasonic defects, applied to a welding system for electrode tabs and electrode sheets, the welding system comprising a controller and a welding device electrically connected to the controller, the welding device comprising a welding base (100) and a welding head (200), characterized in that, Includes the following steps: Step 1: Place the tabs (400) and electrode plates (500) to be welded onto the welding base (100) and perform the first ultrasonic welding. Step 2: The controller determines whether the lifting delay time t4 of the welding head (200) meets the set conditions. If it meets the set conditions, a second ultrasonic test is performed. The set conditions are: 0ms ≤ (holding time t1 + second ultrasonic delay time t2) - (lifting delay time t4 + welding cylinder recovery compression time t3) ≤ 5ms. The welding cylinder recovery compression time t3 is determined by the welding cylinder (300) of the welding device. The welding cylinder (300) is set with a pressing position and a disengagement position during operation. The pressing position is set so that the welding head (200) is pressed down to the electrode tab (400) and the electrode plate. (500) Matching position, and the welding head (200) moves upward at a preset speed from the pressing position until the electrode (400) and the electrode (500) can be pulled under the welding seat (100). At this time, the position of the welding head (200) is the disengagement position, so that the recovery compression time t3 of the welding machine cylinder is set to the time value of the welding head (200) from the pressing position to the disengagement position by the controller through multiple monitoring until a steady state is reached. If the set condition is not met, the controller will adjust the lifting delay time t4 according to the set condition and then perform a second ultrasonic test. Step 3: The controller determines whether the welding joint of the tab (400) and the electrode (500) is stuck to the welding head (200). If so, an alarm is triggered; otherwise, the welding is completed.

2. The welding control method for eliminating secondary ultrasonic defects as described in claim 1, characterized in that: In step two, the preset speed is set to 5mm / s-80mm / s.

3. The welding control method for eliminating secondary ultrasonic defects as described in claim 1, characterized in that: In step two, the pressure holding time t1 and the secondary ultrasonic delay time t2 are set according to the set parameters.

4. The welding control method for eliminating secondary ultrasonic defects as described in claim 3, characterized in that: The set parameters include welding pressure, amplitude, and welding time.

5. A welding system comprising the welding control method as described in any one of claims 1-4, characterized in that, The welding system includes at least the welding apparatus and the controller connected to the welding apparatus; The controller includes: Storage module (1) is used to store the pressure holding time t1, the secondary ultrasonic delay time t2, and the welding machine cylinder recovery compression time t3; The judgment module (2) is used to determine whether the lifting delay time t4 meets the set conditions, and is also used to determine whether the welding joint of the tab (400) and the electrode (500) is stuck to the welding head (200); The adjustment module (3) is used to adjust the lift-up delay time t4; The detection module (4) is used to detect the weld between the tab (400) and the electrode (500) and transmit the data back to the judgment module (2). Alarm module (5), used for alarm; The welding device includes at least the welding base (100), the welding head (200), and the welding cylinder (300). The welding base (100) is provided corresponding to the welding head (200), and the welding cylinder (300) is connected to the welding head (200) and is used to drive the welding head (200).

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