New energy automobile power battery ultrasonic welding pseudo soldering prevention monitoring system and device

Abstract

The invention provides a new energy automobile power battery ultrasonic welding pseudo soldering prevention monitoring system and device.The monitoring system comprises a processor, an impedance monitoring module, an ultrasonic visual monitoring module, an M-type ultrasonic imaging module, a signal processing module and a characteristic value analysis module; the impedance monitoring module is connected with a welding area through a wire, the ultrasonic visual monitoring module is installed over the welding area, the M-type ultrasonic imaging module is arranged on the right side of the ultrasonic visual monitoring module, the signal processing module is arranged on the right side of the welding area, and the characteristic value analysis module is arranged below the signal processing module. According to the invention, the accuracy and real-time performance of pseudo soldering detection are improved; comprehensive monitoring and data analysis of the welding process are realized; potential safety risks are reduced through an early warning mechanism; the user interaction experience and the operation convenience of the system are enhanced; remote monitoring and data analysis are supported, and the production efficiency and the quality control level are improved.

Description

Technical Field

[0001] The present application relates to the technical field of cold weld monitoring systems, and in particular to a new energy vehicle power battery ultrasonic welding cold weld prevention monitoring system and device. Background Art

[0002] New energy vehicles refer to vehicles that use unconventional vehicle fuels as their power source (or use conventional vehicle fuels and new vehicle power devices), and integrate advanced technologies in vehicle power control and drive to form vehicles with advanced technical principles, new technologies, and new structures. New energy vehicles include pure electric vehicles, extended-range electric vehicles, hybrid vehicles, fuel cell electric vehicles, hydrogen engine vehicles, etc.

[0003] New energy vehicle battery packs consist of multiple batteries stacked in series. A typical battery pack has about 96 batteries, and for lithium-ion batteries charged to 4.2V, such a battery pack can produce a total voltage of more than 400V. Although the automotive power system treats the battery pack as a single high-voltage battery and charges and discharges the entire battery pack each time, the battery control system must consider the situation of each battery independently. If the capacity of one battery in the battery pack is slightly lower than that of the other batteries, then after multiple charge / discharge cycles, its charge state will gradually deviate from the other batteries.

[0004] In the manufacturing process of new energy vehicle power batteries, ultrasonic welding is an important connection technology, and its quality directly affects the performance and safety of the battery. Cold welding is one of the common defects in the welding process, which will cause problems such as circuit breakage or increased resistance of the battery pack during use, and may even cause safety accidents in severe cases. Therefore, real-time monitoring and prevention of cold welding is crucial to ensure product quality. Therefore, a new energy vehicle power battery ultrasonic welding cold welding prevention monitoring system and device is designed. Summary of the invention

[0005] The present application provides a new energy vehicle power battery ultrasonic welding anti-cold weld monitoring system and device to solve the problem of low monitoring efficiency in the prior art, realize real-time monitoring of the welding process, accurately identify the cold weld phenomenon, and promptly notify the operator to take corresponding measures through the early warning mechanism.

[0006] The present application provides a new energy vehicle power battery ultrasonic welding anti-false weld monitoring system, the monitoring system includes a processor, an impedance monitoring module, an ultrasonic visualization monitoring module, an M-type ultrasonic imaging module, a signal processing module and a characteristic value analysis module;

[0007] The impedance monitoring module is arranged on the left side of the welding area, the impedance monitoring module is connected to the processor, and the impedance monitoring module is connected to the welding area through a wire, and the impedance monitoring module is used to measure the impedance value of the welding system and determine whether there is a cold welding phenomenon;

[0008] The ultrasonic visualization monitoring module is installed directly above the welding area, the M-type ultrasonic imaging module is arranged on the right side of the ultrasonic visualization monitoring module, the signal processing module is arranged on the right side of the welding area, and the eigenvalue analysis module is arranged below the signal processing module. The ultrasonic visualization monitoring module is connected to the M-type ultrasonic imaging module, the signal processing module, and the eigenvalue analysis module in sequence, and the eigenvalue analysis module is connected to the processor; the ultrasonic visualization monitoring module analyzes the echo signal characteristics to realize the visual monitoring of the cold welding; the M-type ultrasonic imaging module is used to matrix the A-type echo signal to generate an M-type image, intuitively display the process of the weld core formation, and identify the cold welding point; the signal processing module adopts moving average filtering and wavelet denoising technology to improve the signal-to-noise ratio of the ultrasonic signal and enhance the accuracy of cold welding identification; the eigenvalue analysis module establishes a mathematical model by analyzing the eigenvalues ​​such as the sound path difference, the weld core diameter and the height in the ultrasonic echo signal to predict the occurrence of the cold welding phenomenon.

[0009] Preferably, it also includes an alarm module, which is connected to the processor and is used to immediately send out an audible and visual alarm signal when a cold soldering phenomenon is detected, so as to remind the operator to take corresponding measures.

[0010] Preferably, it also includes a data transmission module, and the processor is connected to the cloud server through the data transmission module. The data transmission module uploads the monitoring data to the cloud server in real time to facilitate remote monitoring and management.

[0011] Preferably, it also includes a self-diagnosis module, which is connected to the processor. The self-diagnosis module regularly checks the working status of the system itself and automatically performs calibration or prompts maintenance when an abnormality is found.

[0012] Preferably, it also includes a user operation interface, which is connected to the processor, and provides a user-friendly operation interface, supports display in multiple languages, and can customize personalized monitoring plans according to user needs.

[0013] Preferably, a high-precision impedance measurement circuit is provided in the impedance monitoring module, which can capture and record tiny impedance changes during the welding process in real time.

[0014] Preferably, an ultrasonic probe and a high-resolution display screen are provided in the ultrasonic visualization monitoring module, wherein the ultrasonic probe is used to emit ultrasonic pulses and analyze echo signal characteristics to realize visual monitoring of cold solder joints; the high-resolution display screen displays the echo signal image captured by the ultrasonic probe and provides a user interface for the operator to adjust monitoring parameters.

[0015] Preferably, an adaptive filter is provided in the signal processing module to dynamically adjust the filter parameters according to the real-time signal characteristics.

[0016] Preferably, a method for using a new energy vehicle power battery ultrasonic welding anti-false weld monitoring system comprises the following steps:

[0017] A. During welding, the impedance monitoring module is used to measure the impedance value of the welding system and determine whether there is a cold soldering phenomenon;

[0018] B. At the same time, the ultrasonic probe is used to emit ultrasonic pulses and analyze the echo signal characteristics for visual monitoring of cold solder joints;

[0019] C. Afterwards, the M-mode ultrasonic imaging module processes the A-mode echo signal in a matrix to generate an M-mode image, which intuitively displays the nugget formation process and identifies the cold solder joints;

[0020] D. The ultrasonic imaging signal is transmitted to the signal processing module, which dynamically adjusts the filtering parameters according to the real-time signal characteristics to optimize the signal-to-noise ratio;

[0021] E. The optimized signal is transmitted to the characteristic value analysis module, which establishes a mathematical model to predict the occurrence of cold welding by analyzing the characteristic values ​​such as the sound path difference, the diameter and height of the weld nugget in the ultrasonic echo signal;

[0022] F. When a cold soldering phenomenon is detected, the alarm module can immediately send out an audible and visual alarm signal to remind the operator to take corresponding measures;

[0023] G. At the same time, the processor uploads the monitoring data to the cloud server in real time for remote monitoring and management.

[0024] Preferably, a new energy vehicle power battery ultrasonic welding anti-false weld monitoring device comprises the above-mentioned monitoring system.

[0025] Beneficial effects: The present invention has a high degree of intelligence, which improves the accuracy and real-time performance of cold weld detection; realizes comprehensive monitoring and data analysis of the welding process; reduces potential safety risks through an early warning mechanism; enhances the user interaction experience and operational convenience of the system; supports remote monitoring and data analysis, and improves production efficiency and quality control level; through real-time monitoring and precise analysis, significantly improves welding quality, reduces production costs, and enhances product safety performance.

[0026] The above description is only an overview of the technical solution of the embodiment of the present application. In order to more clearly understand the technical means of the embodiment of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the embodiment of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present application, a brief introduction will be given below to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 This is a principle block diagram of the present invention;

[0029] Figure 2 This is a principle block diagram of the ultrasonic visualization monitoring module of the present invention;

[0030] Figure 3 It is the work flow chart of the present invention;

[0031] Explanation of the accompanying drawings: processor 1, impedance monitoring module 2, ultrasonic visualization monitoring module 3, M-type ultrasonic imaging module 4, signal processing module 5, characteristic value analysis module 6, welding area 7, alarm module 8, data transmission module 9, cloud server 10, self-diagnosis module 11, user operation interface 12. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used in the specification of the application are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" and any variations thereof in the specification, claims and drawings of this application are intended to cover non-exclusive inclusions.

[0034] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase "embodiments" in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0035] The directional words appearing in the following description are all directions shown in the drawings, and do not limit the specific structure of the present application. For example, in the description of the present application, the directions or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. are based on the directions or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present application.

[0036] In addition, the expressions of indicated directions such as the X direction, the Y direction, and the Z direction used to illustrate the operation and construction of the components of the present embodiment are not absolute but relative, and although these indications are appropriate when the components are in the positions shown in the figures, when these positions change, these directions should be interpreted differently to correspond to the changes.

[0037] In addition, the terms "first", "second", etc. in the specification and claims of this application or the above-mentioned drawings are used to distinguish different objects rather than to describe a specific order, and may explicitly or implicitly include one or more of the features.

[0038] In the description of the present application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, the "connection" or "connection" of a mechanical structure may refer to a physical connection. For example, the physical connection may be a fixed connection, such as a fixed connection through a fixing member, such as a fixed connection through a screw, bolt or other fixing member; the physical connection may also be a detachable connection, such as a mutual snap-on or snap-fit ​​connection; the physical connection may also be an integral connection, such as a connection formed by welding, bonding or integral molding. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0039] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings.

[0040] Embodiment 1:

[0041] See also Figure 1-Figure 3 The present application discloses a new energy vehicle power battery ultrasonic welding anti-false welding monitoring system, the monitoring system includes a processor 1, an impedance monitoring module 2, an ultrasonic visualization monitoring module 3, an M-type ultrasonic imaging module 4, a signal processing module 5 and a characteristic value analysis module 6;

[0042] The impedance monitoring module 2 is arranged on the left side of the welding area 7, the impedance monitoring module 2 is connected to the processor 1, and the impedance monitoring module 2 is connected to the welding area 7 through a wire, and the impedance monitoring module 2 is used to measure the impedance value of the welding system and determine whether there is a cold welding phenomenon;

[0043] The ultrasonic visualization monitoring module 3 is installed directly above the welding area 7, the M-type ultrasonic imaging module 4 is arranged on the right side of the ultrasonic visualization monitoring module 3, the signal processing module 5 is arranged on the right side of the welding area 7, and the eigenvalue analysis module 6 is arranged below the signal processing module 5. The ultrasonic visualization monitoring module 3 is connected to the M-type ultrasonic imaging module 4, the signal processing module 5, and the eigenvalue analysis module 6 in sequence, and the eigenvalue analysis module 6 is connected to the processor 1; the ultrasonic visualization monitoring module analyzes the echo signal characteristics to realize the visual monitoring of the cold welding; the M-type ultrasonic imaging module is used to matrix the A-type echo signal to generate an M-type image, intuitively display the process of the molten core formation, and identify the cold welding solder joints; the signal processing module adopts moving average filtering and wavelet denoising technology to improve the signal-to-noise ratio of the ultrasonic signal and enhance the accuracy of cold welding identification; the eigenvalue analysis module establishes a mathematical model by analyzing the eigenvalues ​​such as the sound path difference, the diameter and height of the molten core in the ultrasonic echo signal, predicts the occurrence of the cold welding phenomenon, and uses machine learning technology to improve the accuracy and reliability of the prediction by learning from historical data.

[0044] In the present invention, a high-precision impedance measurement circuit 13 is provided in the impedance monitoring module 2, which can capture and record the tiny impedance changes during the welding process in real time.

[0045] In the present invention, an ultrasonic probe 14 and a high-resolution display screen 15 are set in the ultrasonic visualization monitoring module 3. The ultrasonic probe is used to emit ultrasonic pulses and analyze the echo signal characteristics to achieve visual monitoring of cold solder joints; the high-resolution display screen displays the echo signal image captured by the ultrasonic probe and provides a user interface for the operator to adjust the monitoring parameters.

[0046] In the present invention, an adaptive filter 16 is provided in the signal processing module 5 to dynamically adjust the filter parameters according to the real-time signal characteristics to optimize the signal-to-noise ratio.

[0047] Embodiment 2:

[0048] A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system, the monitoring system includes a processor 1, an impedance monitoring module 2, an ultrasonic visualization monitoring module 3, an M-type ultrasonic imaging module 4, a signal processing module 5 and a characteristic value analysis module 6. This embodiment also includes an alarm module 8, the alarm module 8 is connected to the processor 1, and the alarm module is used to immediately send out an audible and visual alarm signal when a false weld phenomenon is detected, to remind the operator to take corresponding measures.

[0049] Embodiment three:

[0050] A monitoring system for preventing false welds in ultrasonic welding of power batteries for new energy vehicles, the monitoring system comprising a processor 1, an impedance monitoring module 2, an ultrasonic visualization monitoring module 3, an M-type ultrasonic imaging module 4, a signal processing module 5, a characteristic value analysis module 6, and an alarm module 8. This embodiment also includes a data transmission module 9, which can be seamlessly integrated with existing welding equipment, and realizes data transmission and command control through a standard interface. The processor 1 is connected to a cloud server 10 through the data transmission module 9, and the data transmission module uploads the monitoring data to the cloud server in real time, which is convenient for remote monitoring and management.

[0051] Embodiment 4:

[0052] A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system, the monitoring system includes a processor 1, an impedance monitoring module 2, an ultrasonic visualization monitoring module 3, an M-type ultrasonic imaging module 4, a signal processing module 5, a characteristic value analysis module 6, an alarm module 8, and a data transmission module 9. This embodiment also includes a self-diagnosis module 11, which is connected to the processor 1. The self-diagnosis module regularly checks the working status of the system itself and automatically calibrates or prompts maintenance when an abnormality is found; it also includes a user operation interface 12, which is connected to the processor 1. The user operation interface 12 provides a user-friendly operation interface, supports display in multiple languages, and can customize personalized monitoring plans according to user needs.

[0053] Working principle: A method for using a new energy vehicle power battery ultrasonic welding anti-false weld monitoring system, comprising the following steps:

[0054] A. During welding, the impedance monitoring module is used to measure the impedance value of the welding system and determine whether there is a cold soldering phenomenon;

[0055] B. At the same time, the ultrasonic probe is used to emit ultrasonic pulses and analyze the echo signal characteristics for visual monitoring of cold solder joints;

[0056] C. Afterwards, the M-mode ultrasonic imaging module processes the A-mode echo signal in a matrix to generate an M-mode image, which intuitively displays the nugget formation process and identifies the cold solder joints;

[0057] D. The ultrasonic imaging signal is transmitted to the signal processing module, which dynamically adjusts the filtering parameters according to the real-time signal characteristics to optimize the signal-to-noise ratio;

[0058] E. The optimized signal is transmitted to the characteristic value analysis module, which establishes a mathematical model to predict the occurrence of cold welding by analyzing the characteristic values ​​such as the sound path difference, the diameter and height of the weld nugget in the ultrasonic echo signal;

[0059] F. When a cold soldering phenomenon is detected, the alarm module can immediately send out an audible and visual alarm signal to remind the operator to take corresponding measures;

[0060] G. At the same time, the processor uploads the monitoring data to the cloud server in real time for remote monitoring and management.

[0061] In addition, the present invention also discloses a new energy vehicle power battery ultrasonic welding anti-false weld monitoring device. The monitoring device includes the above-mentioned monitoring system, which can realize real-time monitoring of the welding process, accurately identify the false weld phenomenon, and promptly notify the operator to take corresponding measures through the early warning mechanism.

[0062] In summary, the present invention has a high degree of intelligence, which improves the accuracy and real-time performance of cold weld detection; realizes comprehensive monitoring and data analysis of the welding process; reduces potential safety risks through an early warning mechanism; enhances the user interaction experience and operational convenience of the system; supports remote monitoring and data analysis, and improves production efficiency and quality control level; and through real-time monitoring and precise analysis, significantly improves welding quality, reduces production costs, and enhances product safety performance.

[0063] As described above, the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A new energy vehicle power battery ultrasonic welding anti-false welding monitoring system, characterized in that: The monitoring system comprises a processor (1), an impedance monitoring module (2), an ultrasonic visualization monitoring module (3), an M-type ultrasonic imaging module (4), a signal processing module (5) and a characteristic value analysis module (6); The impedance monitoring module (2) is arranged on the left side of the welding area (7), the impedance monitoring module (2) is connected to the processor (1), and the impedance monitoring module (2) is connected to the welding area (7) via a wire, and the impedance monitoring module (2) is used to measure the impedance value of the welding system and determine whether there is a cold welding phenomenon; The ultrasonic visualization monitoring module (3) is installed directly above the welding area (7), the M-type ultrasonic imaging module (4) is arranged on the right side of the ultrasonic visualization monitoring module (3), the signal processing module (5) is arranged on the right side of the welding area (7), and the characteristic value analysis module (6) is arranged below the signal processing module (5). The ultrasonic visualization monitoring module (3) is connected to the M-type ultrasonic imaging module (4), the signal processing module (5), and the characteristic value analysis module (6) in sequence, and the characteristic value analysis module (6) is connected to the processor (1); the ultrasonic visualization monitoring module analyzes the echo signal characteristics to realize the visual monitoring of the cold welding; the M-type ultrasonic imaging module is used to matrix the A-type echo signal to generate an M-type image, intuitively display the process of the weld nugget formation, and identify the cold welding point; the signal processing module adopts moving average filtering and wavelet denoising technology to improve the signal-to-noise ratio of the ultrasonic signal and enhance the accuracy of cold welding identification; the characteristic value analysis module establishes a mathematical model by analyzing the characteristic values ​​such as the sound path difference, the weld nugget diameter and the height in the ultrasonic echo signal to predict the occurrence of the cold welding phenomenon.

2. A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system according to claim 1, characterized in that: It also comprises an alarm module (8), which is connected to the processor (1) and is used to immediately send out an audible and visual alarm signal when a cold soldering phenomenon is detected, so as to remind the operator to take corresponding measures.

3. According to claim 1, a new energy vehicle power battery ultrasonic welding anti-false welding monitoring system is characterized in that: It also includes a data transmission module (9), and the processor (1) is connected to a cloud server (10) via the data transmission module (9). The data transmission module uploads the monitoring data to the cloud server in real time, facilitating remote monitoring and management.

4. A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system according to claim 1, characterized in that: It also includes a self-diagnosis module (11), which is connected to the processor (1). The self-diagnosis module regularly checks the working status of the system itself and automatically performs calibration or prompts maintenance when an abnormality is found.

5. According to claim 1, a new energy vehicle power battery ultrasonic welding anti-false welding monitoring system is characterized in that: It also includes a user operation interface (12), which is connected to the processor (1), and provides a user-friendly operation interface, supports display in multiple languages, and can customize a personalized monitoring plan according to user needs.

6. A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system according to claim 1, characterized in that: A high-precision impedance measurement circuit (13) is arranged in the impedance monitoring module (2), which can capture and record minute impedance changes during the welding process in real time.

7. A new energy vehicle power battery ultrasonic welding anti-false weld monitoring system according to claim 1, characterized in that: An ultrasonic probe (14) and a high-resolution display screen (15) are arranged in the ultrasonic visualization monitoring module (3). The ultrasonic probe is used to emit ultrasonic pulses and analyze echo signal characteristics to achieve visual monitoring of cold solder joints. The high-resolution display screen displays the echo signal image captured by the ultrasonic probe and provides a user interface for an operator to adjust monitoring parameters.

8. The new energy vehicle power battery ultrasonic welding anti-false weld monitoring system according to claim 1 is characterized in that: An adaptive filter (16) is arranged in the signal processing module (5) to dynamically adjust the filter parameters according to the real-time signal characteristics.

9. A method for using the ultrasonic welding anti-false welding monitoring system for a new energy vehicle power battery according to claim 1, characterized in that: The method of use includes the following steps: A. During welding, the impedance monitoring module is used to measure the impedance value of the welding system and determine whether there is a cold soldering phenomenon; B. At the same time, the ultrasonic probe is used to emit ultrasonic pulses and analyze the echo signal characteristics for visual monitoring of cold solder joints; C. Afterwards, the M-mode ultrasonic imaging module processes the A-mode echo signal in a matrix to generate an M-mode image, which intuitively displays the nugget formation process and identifies the cold solder joints; D. The ultrasonic imaging signal is transmitted to the signal processing module, which dynamically adjusts the filtering parameters according to the real-time signal characteristics to optimize the signal-to-noise ratio; E. The optimized signal is transmitted to the characteristic value analysis module, which establishes a mathematical model to predict the occurrence of cold welding by analyzing the characteristic values ​​such as the sound path difference, the diameter and height of the weld nugget in the ultrasonic echo signal; F. When a cold soldering phenomenon is detected, the alarm module can immediately send out an audible and visual alarm signal to remind the operator to take corresponding measures; G. At the same time, the processor uploads the monitoring data to the cloud server in real time for remote monitoring and management.

10. A new energy vehicle power battery ultrasonic welding anti-false welding monitoring device, characterized in that: The monitoring device comprises the monitoring system contained in any one of claims 1 to 9 above.

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