Tab cracking early warning system and method

Abstract

The application belongs to the technical field of industrial control, and discloses a tab cracking early warning system and method. The system comprises an upper computer, a control device and a reference element. The control device is used for controlling the machining station to machine the reference element and recording the working parameters of the control device. The upper computer is used for screening the tensile force data, determining the tensile force abnormal points, and determining the early warning result according to the working parameters of the control device and the tensile force abnormal points. The actual machining condition of the product is simulated, the problems in the machining process are found from the perspective of the product, the tensile force data generated on the product in the production are read, the tensile force data in the production process are monitored, and whether the production process has the product cracking risk is judged through whether the tensile force is out of limit. The accuracy and comprehensiveness of the cracking risk detection are improved.

Description

Technical Field

[0001] This invention relates to the field of industrial control technology, and in particular to a tab cracking early warning system and method. Background Technology

[0002] In industrial production processes, such as ultrasonic welding, flexible connections, and packaging, the connection between two structures may be achieved using flexible materials or sheet metal. During actual production, some processes can cause changes in the distance between the two structures, potentially subjecting the connection to tensile / compressive forces. When the tensile / compressive forces on the connection exceed its yield strength, it can lead to tab cracking, thereby affecting battery performance and safety.

[0003] Currently, there is no effective means in the industry to monitor and control the tensile force on the electrode during the production process in real time. This makes it easy for some structures in the electrode to crack under excessive stress, affecting the yield and reliability of the product.

[0004] The above content is only used to help understand the technical solution of the present invention and does not represent an admission that the above content is prior art. Summary of the Invention

[0005] The main objective of this invention is to provide a tab cracking early warning system and method, which aims to solve the technical problem that the cracking process of existing products is difficult to detect.

[0006] To achieve the above objectives, the present invention provides a tab cracking early warning system. The system includes: a host computer, a control device, and a reference component. The host computer is communicatively connected to the control device and has a communication interface for establishing a communication link with the reference component. The reference component has a testing unit. The system includes: the control device for controlling a processing station to process the reference component and recording the operating parameters of the control device; the reference component for recording tensile data from the testing unit; the host computer for acquiring the operating parameters of the control device and the tensile data from the testing unit; and the host computer for filtering the tensile data, identifying tensile anomalies, and determining an early warning result based on the operating parameters of the control device and the tensile anomalies.

[0007] It should be noted that the reference component records the tensile force it experiences during processing. This data is then processed by a host computer to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0008] In some embodiments, the host computer is used to query the operating parameters of the control device based on the tensile anomaly point to obtain the operating condition information corresponding to the tensile anomaly point, wherein the timestamp corresponding to the tensile anomaly point corresponds one-to-one with the working timestamp corresponding to the operating condition information.

[0009] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the anomalies in tensile data is the only way to solve the problem. By using timestamps to link the working conditions of the processing station with the changes in tensile data, the correlation between anomalies in tensile data and working conditions is realized. This allows us to identify which production processes caused the anomalies and improves the efficiency of anomaly handling.

[0010] In some embodiments, the control device further includes: an identification acquisition device; the identification acquisition device is used to detect the identification information of the reference piece and generate a trigger signal based on the identification information; the control device is used to respond to the trigger signal and generate a time reference point; the control device is used to record the working condition information of the processing station and generate a working timestamp corresponding to the working condition information based on the time reference point; the control device is used to generate working parameters of the control device based on the working condition information of the processing station and the working timestamp corresponding to the working condition information.

[0011] It should be noted that by utilizing the identification and acquisition device of the control equipment, the start time of processing can be accurately and automatically determined. By automatically activating the control equipment and determining the start time node, the efficiency of the detection process is improved.

[0012] In some embodiments, the reference element further includes: a sensor, on which the test part is fixed; the sensor is used to detect tensile force data on the test part.

[0013] It should be noted that by setting the connection between the sensor and the test section on the reference part, the stress change of the test section during the overall processing can be obtained directly and effectively. Especially when the test section is made of tab material and the reference part is in the form of a battery cell, the stress on the tab can be detected intuitively, improving the accuracy of stress detection.

[0014] In some embodiments, the sensor is a triaxial force sensor, and the reference component further includes: a controller; the sensor is used to detect the orthogonal axial force components acting on the test part, the orthogonal axial force components being characterized as three mutually orthogonal axial components in a spatial rectangular coordinate system; the controller is used to synthesize the orthogonal axial force components into a spatial resultant force by torque synthesis, and to generate tensile force data of the test part based on the orthogonal axial force components and the spatial resultant force.

[0015] It should be noted that by setting up a triaxial force sensor, the force on the test part in different directions can be detected. In many processing steps, the tension may not be in the horizontal direction. For example, the welding process may have tensile and compressive forces in different directions. By setting up a triaxial force sensor, the applicability of tensile force detection is improved.

[0016] In some embodiments, the sensor is a triaxial force sensor; the sensor is used to detect the orthogonal axial force components acting on the test part, the orthogonal axial force components being characterized as three mutually orthogonal axial components in a spatial rectangular coordinate system; the host computer is used to synthesize the orthogonal axial force components into a spatial resultant force by torque synthesis, and to generate tensile force data of the test part based on the orthogonal axial force components and the spatial resultant force.

[0017] It should be noted that calculating the resultant force through a host computer can simplify the structure of the reference component and reduce the manufacturing cost of the reference component when simulating a lighter product.

[0018] In some embodiments, the communication interface includes: a wireless communication interface; the wireless communication interface is used to establish a wireless communication link with a reference device.

[0019] It should be noted that by setting up a wireless connection, data can be transmitted to the host computer in real time, anomalies can be detected in a timely manner, and the efficiency of anomaly detection can be improved.

[0020] In some embodiments, the communication interface further includes a wired connection interface; the wired connection interface is used to establish a wired communication connection when the reference part is processed at the processing station.

[0021] It should be noted that the wired connection interface allows data to be imported into the host computer after processing, eliminating the need for an additional communication module and reducing hardware costs.

[0022] Secondly, to achieve the above objectives, the present invention also provides a method for early warning of tab cracking. The method is applied to a host computer and includes: the host computer is communicatively connected to a control device, the control device is used to control a processing station, the host computer is provided with a communication interface, the communication interface is used to establish a communication link with a reference component, the reference component is provided with a testing section, the reference component is used to collect tensile force data of the reference component at the testing section, and the tab cracking early warning method includes: acquiring the operating parameters of the control device; filtering the tensile force data to determine tensile force anomalies; and determining an early warning result based on the operating parameters of the control device and the tensile force anomalies.

[0023] It should be noted that the reference component records the tensile force it experiences during processing. This data is then processed by a host computer to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0024] In some embodiments, the step of filtering the tensile data to determine tensile anomalies includes: filtering the tensile data and determining the time points in the tensile data where the tensile force is not within a preset tensile range as tensile anomalies; the preset tensile range is determined by the material yield strength of the test part.

[0025] It should be noted that by setting a preset tensile range, the tensile force in different directions, such as tension and compression, will not damage the physical structure of the material itself, thus improving the accuracy and versatility of tensile testing.

[0026] In some embodiments, determining the early warning result based on the operating parameters of the control device and the tensile anomaly point includes: determining the working condition information of the processing station and the working timestamp corresponding to the working condition information based on the operating parameters of the control device; determining the timestamp corresponding to the tensile anomaly point based on the tensile anomaly point; matching the timestamp corresponding to the tensile anomaly point with the working timestamp corresponding to the processing station to determine the mapping between the tensile anomaly point and the working condition information; and determining the early warning result based on the mapping between the tensile anomaly point and the working condition information.

[0027] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the anomalies in tensile data is the only way to solve the problem. By using timestamps to link the working conditions of the processing station with the changes in tensile data, the correlation between anomalies in tensile data and working conditions is realized. This allows us to identify which production processes caused the anomalies and improves the efficiency of anomaly handling.

[0028] In some embodiments, determining the early warning result based on the mapping between the tensile anomaly point and the working condition information includes: determining the processing station corresponding to the anomaly point and the anomaly type corresponding to the anomaly point based on the mapping between the tensile anomaly point and the working condition information; and generating an early warning result based on the tensile data of the anomaly point, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point.

[0029] It should be noted that the anomaly type corresponding to the anomaly point can indicate what the anomaly is, and the processing station corresponding to the anomaly point can determine which process the anomaly point occurred in. Providing multiple options for anomaly point information can improve the efficiency of anomaly handling.

[0030] In some embodiments, the testing unit includes a triaxial force sensor and a testing component. The testing component is fixed on the triaxial force sensor. The machining station is used to machine the testing component. The method for obtaining the tensile force data of the reference piece in the testing unit includes: obtaining the orthogonal axial force components of the testing component, wherein the orthogonal axial force components are characterized as three mutually orthogonal axial components in a spatial rectangular coordinate system; performing torque synthesis on the orthogonal axial force components to generate a spatial resultant force; and generating the tensile force data of the testing unit based on the orthogonal axial force components and the spatial resultant force.

[0031] It should be noted that by setting up a triaxial force sensor, the force on the test part in different directions can be detected. In many processing steps, the tension may not be in the horizontal direction. For example, the welding process may have tensile and compressive forces in different directions. By setting up a triaxial force sensor, the applicability of tensile force detection is improved.

[0032] In some embodiments, determining the early warning result based on the operating parameters of the control device and the tension anomaly point includes: determining at least one of the following based on the operating parameters of the control device and the tension anomaly point: tension data of the tension at the anomaly point, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point; determining the corresponding production line information based on the processing station corresponding to the anomaly point; and displaying at least one of the following: production line information, tension data of the anomaly point, processing station corresponding to the anomaly point, and anomaly type corresponding to the anomaly point.

[0033] It should be noted that the anomaly type corresponding to the anomaly point can indicate what the anomaly is, and the processing station corresponding to the anomaly point can determine which process the anomaly point occurred in. Providing multiple options for anomaly point information can improve the efficiency of anomaly handling.

[0034] Thirdly, to achieve the above objectives, the present invention also provides a method for early warning of tab cracking. The method is applied to a control device, which is communicatively connected to a host computer and a processing station. The host computer has a communication interface for establishing a communication link with a reference component. The reference component has a testing section for collecting tensile data from the testing section. The control device is equipped with an identification acquisition device. The method includes: when the identification acquisition device identifies the identification information of the reference component, controlling the processing station to process the reference component and recording the operating parameters of the control device; and sending the operating parameters of the control device to the host computer, so that the host computer generates an early warning result based on the operating parameters of the control device and the tensile data from the testing section.

[0035] It should be noted that the reference component records the tensile force it experiences during processing. This data is then processed by a host computer to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0036] In some embodiments, when the identification acquisition device recognizes the identification information of the reference part, controlling the processing station to process the reference part and recording the operating parameters of the control device includes: when the identification acquisition device recognizes the identification information of the reference part, controlling the processing station to process the reference part and generating a working timestamp corresponding to the processing step, wherein the processing step corresponds to the working condition information; recording the working condition information of the processing station and the working timestamp corresponding to the working condition information; and generating the operating parameters of the control device based on the working condition information of the processing station and the working timestamp corresponding to the working condition information.

[0037] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the anomalies in tensile data is the only way to solve the problem. By using timestamps to link the working conditions of the processing station with the changes in tensile data, the correlation between anomalies in tensile data and working conditions is realized. This allows us to identify which production processes caused the anomalies and improves the efficiency of anomaly handling. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the system architecture of the first embodiment of the electrode cracking early warning system of the present invention;

[0039] Figure 2 This is a schematic diagram of the reference component architecture of an embodiment of the electrode cracking early warning system of the present invention;

[0040] Figure 3 This is a schematic diagram of the cell connection in an embodiment of the electrode cracking early warning system of the present invention;

[0041] Figure 4 This is a schematic diagram of the force on the reference component of the first embodiment of the electrode cracking early warning system of the present invention;

[0042] Figure 5 This is a flowchart illustrating the second embodiment of the electrode cracking early warning method of the present invention;

[0043] Figure 6 This is a schematic diagram of tensile data monitoring in the first embodiment of the electrode tab cracking early warning device of the present invention;

[0044] Icon labels:

[0045] 100: Host computer; 200: Control equipment; 201: Processing station; 300: Reference part; 301: Testing department; 302: Sensor; 303: Controller; 304: Fixing device; 305: Welding object.

[0046] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0047] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0049] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0050] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0051] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0052] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0053] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" 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 the embodiments of this application and simplifying the description, and are not intended to 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 the embodiments of this application.

[0054] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0055] The content disclosed in this application is mainly applied to industrial production. During the processing of products, factors such as mechanical failures and unreasonable parameter settings may cause abnormal stress on the products. For example, in the ultrasonic welding, flexible connection, and casing processes of battery production, the connection between two structures is usually achieved using flexible materials or sheet metal. Because some processes can cause changes in the distance between the two structures, the connection part may be subjected to tensile or compressive forces. Once these forces exceed the yield limit of the material, it will cause the tab to crack, thereby impairing the performance and safety of the battery. Currently, there is no effective means in the industry to monitor and control the tensile force on the tab in real time. This makes the structure prone to cracking under excessive stress during production, ultimately affecting the yield and reliability of the product. In actual production, because some processes may come into contact with the tab or the distance between the two cells may change, the tab may be subjected to tensile forces. When the tensile force on the tab exceeds its yield limit, it will cause the tab to crack, thereby affecting the performance and safety of the battery. Currently, there is no effective means to monitor and control the tensile force on the tabs during the production process in real time. This makes the tabs prone to cracking under excessive force, affecting the yield and reliability of the battery.

[0056] To address the aforementioned issues, the proposed solution involves inputting a reference component into the processing station to simulate the actual product during processing. This involves reading the tab tension data and monitoring the tab tension during the production process. By checking if the tension exceeds the limit (the force required to tear a single-layer tab), the solution determines whether there is a risk of tab cracking during production. The reference component and control equipment (such as a PLC) communicate in real-time to obtain the current equipment actions and cell positions. Timing synchronization is performed using time synchronization. If there is a risk of tab cracking in the cell, the solution further analyzes the tab cracking process curve of the cell and the current equipment actions to determine any anomalies in the current equipment.

[0057] According to some embodiments of this application, such as Figure 1 The diagram illustrates a tab cracking early warning system. The system includes a host computer 100, a control device 200, and a reference component 300. The host computer 100 is communicatively connected to the control device 200 and has a communication interface for establishing a communication link with the reference component 300. The reference component 300 has a testing unit 301. The system includes: the control device 200, used to control the processing station 201 to process the reference component 300 and record the operating parameters of the control device 200; the reference component 300, used to record the tensile force data of the testing unit 301; the host computer 100, used to acquire the operating parameters of the control device 200 and the tensile force data of the testing unit 301; and the host computer 100, used to filter the tensile force data, determine tensile force anomalies, and determine an early warning result based on the operating parameters of the control device 200 and the tensile force anomalies.

[0058] It should be noted that this solution is applicable to industrial production processes. This embodiment can be used to test tensile and compressive forces on any product's connection structure and specific parts. For example, in battery production, assuming the reference component is a cell test model and the testing part is the tab on the cell test model, after ultrasonic welding, the clamps may accidentally scrape against the tabs during cell transfer; or, during the process of installing a cell with welded flexible connections into the battery casing, slight deviations in cell positioning may cause the tabs to be forcibly "squeezed" or "pulled" to align with the installation position. These unavoidable contact and spacing changes in the production process will subject the tabs to additional tensile stress. As thin and narrow metal foils, the tabs have limited tensile strength. When these instantaneous tensile forces exceed their material yield limit, microcracks will occur. These cracks may not affect conductivity initially, but during subsequent charging and discharging of the battery, they will gradually expand due to thermal stress, eventually leading to connection failure, causing battery performance degradation, and even safety hazards. This embodiment does not limit the product itself, but only takes the battery cell manufacturing process and testing methods as an example. It assumes that the reference component 300 is a battery cell test model and the testing unit 301 is the tab on the battery cell test model to illustrate this embodiment. The reference component is a device used to inspect production equipment.

[0059] It is understandable that the host computer 100 serves as a monitoring and management layer device (such as an industrial computer or server), while the control device 200 serves as a field control layer device (such as a programmable logic controller (PLC) or an industrial robot controller). The host computer 100, as the monitoring and management layer device (such as an industrial computer or server), is responsible for data monitoring and scheduling of the entire production system. The control device 200, as the field control layer device (such as a PLC), connects to the host computer for data interaction and direct control of the processing stations 201. These processing stations 201 refer to equipment that performs specific production operations, such as equipment used for ultrasonic welding, battery cell casing installation, and other related processes.

[0060] It should be noted that the host computer 100 is equipped with a communication interface, which is used to establish a communication link with the reference device 300. The communication interface can be a wired communication interface or a wireless communication structure. This embodiment does not limit this. For example, there are many types of communication interfaces that can be used between the host computer and the reference device. Wired communication interfaces include common Ethernet ports, serial communication interfaces such as RS-485 or RS-232, and USB interfaces. These are connected by physical cables and have the characteristics of high reliability and strong anti-interference ability. Wireless communication structures include Wi-Fi, Bluetooth, ZigBee, and proprietary wireless protocols for industrial environments. These do not require wiring, provide greater flexibility in device layout, and are suitable for mobile reference devices or industrial sites where wiring is difficult.

[0061] Among them, the control device 200 is used to control the processing station 201 to process the reference part 300 and record the working parameters of the control device 200. In actual production, the host computer can read the working parameters of the PLC (control device) and determine the working status of the processing station and the working time node, thereby understanding the various parameters of the processing.

[0062] In practical implementation, the reference component 300 records the tensile force data of the test unit 301. The shape of the reference component can be manufactured to match the product, for example, it can be made into the shape of a long block after the battery cell is wound and shaped, and then a thin metal sheet similar to an electrode tab is fixed on the block. Figure 2 as well as Figure 3 As shown, in a specific scenario, for example, a reference component in the form of a battery cell is placed in a welding station for ultrasonic welding. The sensor built into the reference component can sense the external force received by the test unit 301 (tab) and record it.

[0063] Furthermore, the host computer 100 filters the tensile data to identify tensile anomalies. By filtering the tensile data, it can identify tensile or compressive forces that may damage the product. If destructive tensile or compressive forces are found, it is considered that there is an anomaly in the production process. The abnormal production process is regarded as a tensile anomaly point. When an anomaly is found, the working parameters of the control equipment 200 are combined to find the working parameters of the PLC at the tensile anomaly point and generate an early warning result.

[0064] It is important to emphasize that the tensile force data in this solution represents either tensile or compressive force. This is because force has direction; a positive tensile force represents tension in the conventional sense, while a negative tensile force represents compressive force in the conventional sense. In this embodiment, the tensile force actually represents the force experienced by the testing unit 301 (electrode). In actual production, the ultrasonic welding process actually involves... Figure 2 as well as Figure 3 The process of welding the test section 301 (electrode) to the welding object 305 (adapter piece) involves measuring the stress on the test section 301 (electrode) during the welding process using a reference component.

[0065] Among them, the working parameters of the control device 200 are the processing parameters collected by the control device from the processing station, such as the working condition information of ultrasonic welding, such as when the ultrasonic equipment performed what operation.

[0066] It should be noted that the reference component 300 records the tensile force it experiences during processing. This value is then processed by the host computer 100 to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0067] In some embodiments, the host computer 100 is used to query the working parameters of the control device 200 based on the tension anomaly point to obtain the working condition information corresponding to the tension anomaly point, and the timestamp corresponding to the tension anomaly point corresponds one-to-one with the working timestamp corresponding to the working condition information.

[0068] It should be noted that tab cracking is a typical equipment anomaly in battery production. Currently, its risk is mainly assessed indirectly by detecting a series of control points, such as critical fixture dimensions, wear of the forming cover, abnormal welding machine parameters, the linkage between the welding cover and the welding head, excessive welding pressure, stress concentration in the welding head, clamp misalignment, abnormal welding gaps, and tray impact. However, the current assessment of these anomalies still relies on manual identification. Specifically, critical dimensions require manual coordinate measuring machine (CMM) measurement, equipment parameters are only passively monitored, production data is not used for specific analysis of tab cracking, and dynamic process parameters such as tab posture, surface stress, tab tension, and bare cell spacing cannot be analyzed and detected in real time.

[0069] It is important to note that during the ultrasonic welding-flexible connection-casing process, the connection between the two cells mainly relies on the connection between the test section 301, the welding object 305, and the test section 301 (tab-adapter-tab). If there is any pulling between the two cells, the tab will be subjected to stress. If the stress exceeds the tab's capacity, such as... Figure 3 As shown.

[0070] Therefore, the existing testing methods described above have several problems. First, in terms of critical dimension measurement, manual operation is inefficient, and the measurement results are easily affected by the operator's technique and skill level. Furthermore, the measurement process requires machine downtime, directly impacting production capacity. More critically, in the production process where two bare cells are connected via tabs and adapter plates, the spacing between the bare cells can change during gripping, transport, and fixture fixing, easily causing drastic fluctuations in the tension of the tabs, resulting in a very high risk of tab cracking. Currently, there is a lack of effective monitoring methods for the stress on the cells during the process, making it impossible to detect and warn of this critical risk in real time, constituting a significant blind spot in quality control.

[0071] As can be seen from the above, the cracking of the tab is distributed in multiple working conditions, which is difficult to detect and even more difficult to control uniformly. This solution is to send the reference part into multiple different processing stations for processing and detect the tab tension parameters during processing to determine the cracking. However, the ultimate goal is to locate the cracking process. Therefore, it is very important to correlate the time of cracking with the process flow of the processing station.

[0072] It is understandable that this embodiment achieves this by using the same time rule in both the control device and the reference component. It only requires associating the tensile force data in the reference component with time, then associating the processing parameters collected by the control device (such as the operation of the welding equipment, the operation of the robotic arm, the movement of the conveyor belt, etc.) with time, and finally synchronizing the time. This allows the association of tensile force data with the processing process. By synchronizing the time of the processing condition (condition information) in the working parameters corresponding to the tensile force anomaly point, the condition information corresponding to the tensile force anomaly point can be obtained.

[0073] Ultrasonic welding involves transmitting high-frequency vibrations of tens of thousands of times per second to the surfaces of two metal workpieces to be welded. The welding pressure causes the metal surfaces to rub against each other, forming a fusion between molecular layers, thus achieving the welding purpose. Tab cracking occurs when the tab is subjected to external force. The tab connects the internal electrodes (positive / negative) of the battery cell to the external circuitry, and is typically a thin metal sheet (such as aluminum or copper). The adapter plate is a conductive metal sheet connecting the battery cell tab to external circuitry (such as busbars, sampling lines, BMS, etc.), usually made of copper, aluminum, or nickel. During the process, some components may come into contact with the tab, or changes in the distance between the two battery cells may cause tension, resulting in the tab being subjected to tensile force. When the force on the tab exceeds its limit, it will cause the tab to crack.

[0074] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the tensile anomaly is the only way to solve the problem. By using timestamps to link the working conditions of processing station 201 with the tensile data change process, the correlation between tensile data anomalies and working conditions is realized. This allows us to discover which production processes caused the tensile anomalies and improves the efficiency of anomaly handling.

[0075] In some embodiments, the control device 200 further includes: an identification acquisition device; the identification acquisition device is used to detect the identification information of the reference piece 300 and generate a trigger signal based on the identification information; the control device 200 is used to generate a time reference point in response to the trigger signal; the control device 200 is used to record the working condition information of the processing station 201 and generate a working timestamp corresponding to the working condition information based on the time reference point; the control device 200 is used to generate working parameters of the control device 200 based on the working condition information of the processing station 201 and the working timestamp corresponding to the working condition information.

[0076] It should be noted that the identification acquisition device can be a barcode scanner or an image acquisition device. It is realized by acquiring identification information set on the reference piece or identifying the reference piece. The identification information can be a barcode, QR code or other identification image, or a triggering device such as an electronic chip.

[0077] The system automatically activates the control equipment by triggering a signal generated by the identification information, thereby controlling the processing station to start the test cycle. The test cycle involves processing the reference part and obtaining the working status of each station during processing, thereby generating the working parameters of the control equipment.

[0078] In this specific implementation, the following method is provided for unified construction and synchronization: The reference component 300 is started. Assuming the reference component and the host computer are wirelessly connected, a wireless connection is established. When the host computer detects a trigger signal, it initializes sensor data and synchronizes sensor timestamps. The host computer acquires the tensile and compressive data and timestamps of the reference component 300 in real time. The reference component 300 uploads its tensile and compressive data at a frequency of 1000Hz. The host computer records the tensile and compressive data and the acquisition time information of the reference component 300 in real time. The host computer and the PLC establish a connection via TCP. The PLC uploads the location of the reference component 300 in real time, and the host computer collects the location information of the reference component 300 and records the time information.

[0079] It should be noted that by utilizing the identification and acquisition device of the control equipment 200, the start time of processing can be accurately and automatically determined. By automatically activating the control equipment 200 and determining the start time node, the efficiency of the detection process is improved.

[0080] In some embodiments, the reference element 300 further includes: a sensor, on which the test part 301 is fixed; and a sensor for detecting the tensile force data received by the test part 301.

[0081] In specific implementations, such as Figure 2 As shown, by fixing the electrode tab to the measuring end of the sensor and coupling it, the sensor can detect the force (including tensile force and shear force) in real time.

[0082] It should be noted that by setting the connection between the sensor and the test section 301 on the reference part 300, the stress change of the test section 301 during the overall processing can be obtained directly and effectively. Especially when the test section 301 is made of tab material and the reference part 300 is in the form of a battery cell, the stress on the tab can be detected intuitively, thus improving the accuracy of stress detection.

[0083] In some embodiments, the sensor is a triaxial force sensor, and the reference component 300 further includes: a controller; a sensor for detecting the orthogonal axial force components acting on the test unit 301, wherein the orthogonal axial force components are characterized as three axial components that are orthogonal to each other in a spatial rectangular coordinate system; and a controller for generating a spatial resultant force by combining the orthogonal axial force components into torques, and generating tensile data of the test unit 301 based on the orthogonal axial force components and the spatial resultant force.

[0084] It should be noted that a triaxial force sensor is preferred. This is because during actual processing, especially ultrasonic welding, the electrode is subjected to forces in multiple directions, not just tensile forces in the horizontal direction. There may also be compression, folding, and torsion of the electrode. Therefore, a triaxial force sensor can more comprehensively detect the tensile and compressive forces on the electrode tab. The specific setup is as follows: Figure 2 By fixing the electrode tab to a dedicated fixing device 304 (clamping device), which is coupled to the measuring end of a triaxial force sensor 302 (sensor) through a rigid connector, the sensor can detect the force components (including tensile force and shear force) of the electrode tab in the three orthogonal axes of X, Y, and Z in real time. Finally, the controller 303 calculates the spatial resultant force on the electrode tab. The force components in the three orthogonal axes of X, Y, and Z and the spatial resultant force serve as the data basis for judging whether the tension is abnormal.

[0085] It should be noted that by setting a triaxial force sensor, the force on the test section 301 in different directions can be detected. In many processing steps, the tension may not be in the horizontal direction. For example, the welding process may have tensile and compressive forces in different directions. By setting a triaxial force sensor, the applicability of tensile force detection is improved.

[0086] In some embodiments, the sensor is a triaxial force sensor; the sensor is used to detect the orthogonal axial force components that the test unit 301 is subjected to, the orthogonal axial force components being characterized as three axial components that are orthogonal to each other in a spatial rectangular coordinate system; the host computer 100 is used to synthesize the orthogonal axial force components into a spatial resultant force by torque synthesis, and to generate the tension data of the test unit 301 based on the orthogonal axial force components and the spatial resultant force.

[0087] It should be noted that a triaxial force sensor is preferred. This is because during actual processing, especially ultrasonic welding, the electrode is subjected to forces in multiple directions, not just tensile forces in the horizontal direction. There may also be compression, folding, and torsion of the electrode. Therefore, a triaxial force sensor can more comprehensively detect the tensile and compressive forces on the electrode tab. The specific setup is as follows: Figure 2By fixing the electrode tab to a dedicated fixing device 304 (clamping device), which is coupled to the measuring end of a triaxial force sensor 302 (sensor) through a rigid connector, the sensor can detect the force components (including tensile force and shear force) of the electrode tab in the three orthogonal axes of X, Y, and Z in real time. The spatial resultant force on the electrode tab is calculated by a vector synthesis algorithm in the host computer. The force components in the three orthogonal axes of X, Y, and Z and the spatial resultant force serve as the data basis for judging whether the tension is abnormal.

[0088] It should be noted that by calculating the resultant force through the host computer 100, the structure of the reference component 300 can be simplified, and the manufacturing cost of the reference component 300 can be reduced when the reference component 300 simulates a lighter product.

[0089] In some embodiments, the communication interface includes: a wireless communication interface; a wireless communication interface for establishing a wireless communication link with the reference component 300.

[0090] In this specific implementation, this embodiment proposes a scheme for real-time communication between the host computer and the reference component. The wireless communication interface can specifically adopt protocols such as Wi-Fi, Bluetooth, or ZigBee. Its advantage lies in enabling real-time and continuous data transmission, allowing the host computer 100 to instantly acquire the tensile force data collected by the reference component 300 during processing. This allows for rapid response and early warning of abnormal electrode force, greatly improving detection efficiency and the level of intelligent production. Furthermore, the computing unit can be deployed within the host computer, providing more space for the reference component. However, its disadvantages include the potential for interference from the complex electromagnetic environment of the industrial site, posing challenges to data transmission stability and reliability. Additionally, it typically requires a separate power supply module for the reference component 300, potentially leading to higher complexity and cost in hardware integration and long-term maintenance.

[0091] It should be noted that by setting up a wireless connection, data can be transmitted to the host computer 100 in real time, allowing for timely detection of anomalies and improving the efficiency of anomaly detection.

[0092] In some embodiments, the communication interface further includes: a wired connection interface; the wired connection interface is used to establish a wired communication link when the reference part 300 is processed at the processing station 201.

[0093] In other embodiments, a wired connection can be used between the reference device and the host computer. The host computer (PC) communicates wirelessly with the reference device, and a wired connection is established with the PLC via a switch connected to the device's local area network, ultimately enabling data exchange with the PLC. The wired connection interface can specifically adopt standard interfaces such as USB, Ethernet, or RS-485. Its core advantage lies in the extremely stable data transmission and strong anti-interference capability achieved through physical cable connection, and it eliminates the need for complex wireless communication and power supply units for the reference device 300, effectively reducing the hardware cost of a single node. However, its main disadvantage is poor flexibility. Due to the cable constraint, the reference device 300 is not suitable for continuous operation in dynamic production processes. It is typically more suitable for batch data export during processing intervals or after completion, thus failing to achieve true real-time monitoring and exhibiting inherent delays in the immediacy of anomaly detection.

[0094] It should be noted that the data can be imported into the host computer 100 after processing via a wired connection interface, without the need to set up an additional communication module, thus reducing hardware costs.

[0095] Secondly, in order to achieve the above objectives, such as Figure 5 As shown, the present invention also provides a method for early warning of tab cracking. The method is applied to a host computer, which is communicatively connected to a control device. The control device is used to control the processing station. The host computer is equipped with a communication interface for establishing a communication link with a reference part. The reference part is equipped with a testing section for collecting tensile force data of the reference part at the testing section. The method for early warning of tab cracking includes: step S10: obtaining the working parameters of the control device; step S20: filtering the tensile force data to determine the tensile force anomaly point; step S30: determining the early warning result based on the working parameters of the control device and the tensile force anomaly point.

[0096] It should be noted that this solution is applicable to industrial production processes. This embodiment can be used to test tensile and compressive forces on any product's connection structure and specific parts. For example, in battery production, assuming the reference component is a cell test model and the testing part is the tab on the cell test model, after ultrasonic welding, the clamps may accidentally scrape against the tabs during cell transfer; or, during the process of installing a cell with welded flexible connections into the battery casing, slight deviations in cell positioning may cause the tabs to be forcibly "squeezed" or "pulled" to align with the installation position. These unavoidable contact and spacing changes in the production process will subject the tabs to additional tensile stress. As thin and narrow metal foils, the tabs have limited tensile strength. When these instantaneous tensile forces exceed their material yield limit, microcracks will occur. These cracks may not affect conductivity initially, but during subsequent charging and discharging of the battery, they will gradually expand due to thermal stress, eventually leading to connection failure, causing battery performance degradation, and even safety hazards. This embodiment does not limit the product itself, but only uses the battery cell manufacturing process and testing methods as examples. It assumes that the reference component is the battery cell test model and the testing part is the tab on the battery cell test model to illustrate this embodiment. The reference component is a device used to inspect production equipment.

[0097] Understandably, the host computer serves as the monitoring and management layer device (e.g., an industrial computer or server), while the control device serves as the field control layer device (e.g., a programmable logic controller (PLC) or industrial robot controller). The host computer, as the monitoring and management layer device, is responsible for data monitoring and scheduling of the entire production system. The control device, as the field control layer device (e.g., a PLC), connects to the host computer for data interaction and direct control of the processing stations. These processing stations refer to equipment that performs specific production operations, such as equipment used for ultrasonic welding or battery cell casing installation.

[0098] It should be noted that the host computer is equipped with a communication interface, which is used to establish a communication link with the reference device. The communication interface can be a wired communication interface or a wireless communication structure. This embodiment does not limit this. For example, there are many types of communication interfaces that can be used between the host computer and the reference device. Wired communication interfaces include common Ethernet ports, serial communication interfaces such as RS-485 or RS-232, and USB interfaces. These are connected by physical cables and have the characteristics of high reliability and strong anti-interference ability. Wireless communication structures include Wi-Fi, Bluetooth, ZigBee, and proprietary wireless protocols for industrial environments. These do not require wiring, provide greater flexibility in device layout, and are suitable for moving reference devices or industrial sites where wiring is difficult.

[0099] Among them, the control equipment is used to control the processing station to process the reference part and record the working parameters of the control equipment. In actual production, the host computer can read the working parameters of the PLC (control equipment), and thus determine the working status of the processing station and the time node of the work, thereby understanding the various parameters of the processing.

[0100] In practical implementation, the reference component records the tensile force data of the testing department. The shape of the reference component can be manufactured to match the product, for example, it can be made into the shape of a long block after the battery cell is wound and shaped, and then a thin metal sheet similar to an electrode tab is fixed on the block. Figure 2 as well as Figure 3 As shown, in a specific scenario, for example, a reference component in the form of a battery cell is placed in a welding station for ultrasonic welding. The sensor built into the reference component can sense the external force received by the tab (test section) and record it.

[0101] Furthermore, the host computer filters the tensile data to identify tensile anomalies. By filtering the tensile data, it can identify tensile or compressive forces that may damage the product. If destructive tensile or compressive forces are found, it is considered that there is an anomaly in the production process. The abnormal production process is regarded as a tensile anomaly point. When an anomaly is found, the working parameters of the control equipment are combined to find the working parameters of the PLC at the tensile anomaly point and generate an early warning result.

[0102] It is important to emphasize that the tensile force data in this solution represents either tensile or compressive force. This is because force has direction; a positive tensile force represents tension in the conventional sense, while a negative tensile force represents compressive force in the conventional sense. In this embodiment, the tensile force actually represents the force experienced by the testing part (electrode). In actual production, the ultrasonic welding process actually involves... Figure 2 as well as Figure 3 The process of welding the test section (electrode) to the welding object (adapter piece) involves using a reference component to measure the stress on the test section (electrode) during the welding process.

[0103] Among them, the operating parameters of the control equipment are the processing parameters collected by the control equipment at the processing station, such as the working condition information of ultrasonic welding, such as when the ultrasonic equipment performed what operation.

[0104] It should be noted that the reference component records the tensile force it experiences during processing. This data is then processed by a host computer to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0105] In some embodiments, filtering tensile data to determine tensile anomalies includes: filtering tensile data and identifying time points in the tensile data where the tensile force is not within a preset tensile range as tensile anomalies; the preset tensile range is determined by the material yield strength of the testing unit.

[0106] Understandably, the tensile data is filtered based on a key preset tensile range: all time points in the tensile data sequence that are not within this preset tensile range are identified as tensile anomalies. The upper and lower limits of this preset tensile range are determined through engineering calculations and experiments, based on the mechanical properties of the materials used in the testing unit, particularly their yield strength, and are primarily determined by the mechanical properties of single-layer or multi-layer tabs.

[0107] It should be noted that by setting a preset tensile range, the tensile force in different directions, such as tension and compression, will not damage the physical structure of the material itself, thus improving the accuracy and versatility of tensile testing.

[0108] In some embodiments, determining the early warning result based on the operating parameters of the control equipment and the tensile anomaly point includes: determining the working condition information of the processing station and the working timestamp corresponding to the working condition information based on the operating parameters of the control equipment; determining the timestamp corresponding to the tensile anomaly point based on the tensile anomaly point; matching the timestamp corresponding to the tensile anomaly point with the working timestamp corresponding to the processing station to determine the mapping between the tensile anomaly point and the working condition information; and determining the early warning result based on the mapping between the tensile anomaly point and the working condition information.

[0109] It's worth noting that by using the same time rule in both the control equipment and the reference component, it's sufficient to correlate the tensile force data in the reference component with time, then correlate the processing parameters collected by the control equipment (such as the operation of the welding equipment, the operation of the robotic arm, the movement of the conveyor belt, etc.) with time, and finally synchronize the time. This achieves the correlation between tensile force data and the processing process. By synchronizing the time of the processing condition (condition information) in the working parameters corresponding to the tensile force anomaly point, the condition information corresponding to the tensile force anomaly point can be obtained. After the battery cell completes the current process, the host computer merges the data, aligning the PLC's station data with the tensile and compressive force curve data during the battery cell's movement, confirming the tensile and compressive force curves corresponding to each station.

[0110] Among them, working condition information is a representation of the processing process. For example, during the processing, each processing station will generate multiple actions, such as: Figure 6As shown, the vertical axis represents the magnitude of the tension on the coordinate axis, and the horizontal axis represents the processing progress (such as timestamps or workstation steps). There will be actions such as belt pulling upon entering the station, gripping by robotic arm A, moving by robotic arm B, pressing down on the adhesive, applying the adhesive, moving up on the adhesive, etc. The working condition information is used to characterize these actions to synchronize different time nodes, different tension data, and different working conditions. By detecting the values, values ​​that exceed the preset tension range can be identified. The preset tension range is set to simultaneously filter the magnitude of the force in both positive and negative directions, i.e., tension and pressure.

[0111] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the anomalies in tensile data is the only way to solve the problem. By using timestamps to link the working conditions of the processing station with the changes in tensile data, the correlation between anomalies in tensile data and working conditions is realized. This allows us to identify which production processes caused the anomalies and improves the efficiency of anomaly handling.

[0112] In some embodiments, determining the early warning result based on the mapping between tensile anomalies and working condition information includes: determining the processing station corresponding to the anomaly point and the anomaly type corresponding to the anomaly point based on the mapping between tensile anomalies and working condition information; and generating an early warning result based on the tensile data of the anomaly point, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point.

[0113] It should be noted that the type of abnormality can be inferred from the tensile force data under different processing stations and working conditions. For example, the robotic arm may have an excessively long travel distance or excessive adhesive pressure.

[0114] In practice, alarm information is generated from tensile data, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point. The alarm information simultaneously displays tensile data, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point. These three together constitute a complete problem diagnosis and action guidance chain.

[0115] It should be noted that the anomaly type corresponding to the anomaly point can indicate what the anomaly is, and the processing station corresponding to the anomaly point can determine which process the anomaly point occurred in. Providing multiple options for anomaly point information can improve the efficiency of anomaly handling.

[0116] In some embodiments, the testing unit includes a triaxial force sensor and a testing component. The testing component is fixed on the triaxial force sensor, and a machining station is used to process the testing component. The method for obtaining the tensile force data of the reference piece in the testing unit includes: obtaining the orthogonal axial force components of the testing component, wherein the orthogonal axial force components are characterized as three axial components that are orthogonal to each other in a spatial rectangular coordinate system; performing torque synthesis on the orthogonal axial force components to generate a spatial resultant force; and generating the tensile force data of the testing unit based on the orthogonal axial force components and the spatial resultant force.

[0117] It should be noted that a triaxial force sensor is preferred. This is because during actual processing, especially ultrasonic welding, the electrode is subjected to forces in multiple directions, not just tensile forces in the horizontal direction. There may also be compression, folding, and torsion of the electrode. Therefore, a triaxial force sensor can more comprehensively detect the tensile and compressive forces on the electrode tab. The specific setup is as follows: Figure 2 By fixing the electrode tab to a dedicated fixing device 304 (clamping device), which is coupled to the measuring end of a triaxial force sensor 302 (sensor) through a rigid connector, the sensor can detect the force components (including tensile force and shear force) of the electrode tab in the three orthogonal axes of X, Y, and Z in real time. The spatial resultant force on the electrode tab is calculated by a vector synthesis algorithm in the host computer. The force components in the three orthogonal axes of X, Y, and Z and the spatial resultant force serve as the data basis for judging whether the tension is abnormal.

[0118] In the specific implementation, assuming the yield strength of the electrode is X, and the unit of tension and compression of the electrode in the above data is 0.01N. First, to prevent interference from sensor data, the tension and compression data are first filtered using an eighth-order moving average. The average of the current point and the previous seven points is calculated at each step, and this average is used as the filtered output value. Mathematical expression:

[0119]

[0120] x[n] is the original signal, and y[n] is the filtered signal.

[0121] One hundred points of tensile and compressive force detected by the reference component under static conditions are used as data reference values ​​to calibrate the data. Then, the forces along the x, y, and z axes are combined into torques, and the torque directions are calculated. The vector of the point of application of the force is f{r} = (r_x, r_y, r_z)r=(rx, ry, rz), as shown. Figure 4 As shown, the forces in the three directions are: Fx (along the x-axis), Fy (along the y-axis), and Fz (along the z-axis).

[0122] Calculation of the resultant moment modulus:

[0123]

[0124] M represents the resultant torque modulus, and Mx, My, and Mz represent components in different directions. It should be noted that by setting up a triaxial force sensor, the force on the test part in different directions can be detected. In many processing steps, the tension may not be in the horizontal direction. For example, the welding process may involve tensile and compressive forces in different directions. By setting up a triaxial force sensor, the applicability of tensile force detection is improved.

[0125] In some embodiments, determining the early warning result based on the operating parameters of the control device and the tension anomaly point includes: determining at least one of the following based on the operating parameters of the control device and the tension anomaly point: tension data of the tension at the anomaly point, the processing station corresponding to the anomaly point, and the anomaly type corresponding to the anomaly point; determining the corresponding production line information based on the processing station corresponding to the anomaly point; and displaying at least one of the following: production line information, tension data of the anomaly point, processing station corresponding to the anomaly point, and anomaly type corresponding to the anomaly point.

[0126] Understandably, in specific terms, real-time and detailed tension data provides objective and quantitative evidence for alarms, enabling operators to accurately assess the severity of the anomaly and serving as the fundamental basis for determining the nature of the problem. Clearly marked anomaly points corresponding to specific processing stations enable rapid problem localization, directly guiding maintenance personnel's attention to specific equipment on the production line, significantly reducing the time required to troubleshoot the source of the fault and avoiding a needle-in-a-haystack search across the entire production line. Accurately defined anomaly types (such as over-tension, insufficient pressure, or instantaneous impact) directly indicate the nature of the problem, providing crucial direction for subsequent corrective actions, such as adjusting equipment parameters, replacing worn fixtures, or checking the incoming material condition. Production line information refers to the production line where the processing station is located, serving the same purpose as the processing station information, facilitating the identification of the abnormal processing station location.

[0127] It should be noted that the anomaly type corresponding to the anomaly point can indicate what the anomaly is, and the processing station corresponding to the anomaly point can determine which process the anomaly point occurred in. Providing multiple options for anomaly point information can improve the efficiency of anomaly handling.

[0128] Thirdly, to achieve the above objectives, the present invention also provides a method for early warning of tab cracking. The method is applied to a control device, which is communicatively connected to a host computer and a processing station. The host computer has a communication interface for establishing a communication link with a reference component. The reference component has a testing section for collecting tensile data from the testing section. The control device is equipped with an identification acquisition device. The method includes: when the identification acquisition device identifies the identification information of the reference component, controlling the processing station to process the reference component and recording the operating parameters of the control device; and sending the operating parameters of the control device to the host computer, so that the host computer generates an early warning result based on the operating parameters of the control device and the tensile data from the testing section.

[0129] It should be noted that this solution is applicable to industrial production processes. This embodiment can be used to test tensile and compressive forces on any product's connection structure and specific parts. For example, in battery production, assuming the reference component is a cell test model and the testing part is the tab on the cell test model, after ultrasonic welding, the clamps may accidentally scrape against the tabs during cell transfer; or, during the process of installing a cell with welded flexible connections into the battery casing, slight deviations in cell positioning may cause the tabs to be forcibly "squeezed" or "pulled" to align with the installation position. These unavoidable contact and spacing changes in the production process will subject the tabs to additional tensile stress. As thin and narrow metal foils, the tabs have limited tensile strength. When these instantaneous tensile forces exceed their material yield limit, microcracks will occur. These cracks may not affect conductivity initially, but during subsequent charging and discharging of the battery, they will gradually expand due to thermal stress, eventually leading to connection failure, causing battery performance degradation, and even safety hazards. This embodiment does not limit the product itself, but only uses the battery cell manufacturing process and testing methods as examples. It assumes that the reference component is the battery cell test model and the testing part is the tab on the battery cell test model to illustrate this embodiment. The reference component is a device used to inspect production equipment.

[0130] Understandably, the host computer serves as the monitoring and management layer device (e.g., an industrial computer or server), while the control device serves as the field control layer device (e.g., a programmable logic controller (PLC) or industrial robot controller). The host computer, as the monitoring and management layer device, is responsible for data monitoring and scheduling of the entire production system. The control device, as the field control layer device (e.g., a PLC), connects to the host computer for data interaction and direct control of the processing stations. These processing stations refer to equipment that performs specific production operations, such as equipment used for ultrasonic welding or battery cell casing installation.

[0131] It should be noted that the host computer is equipped with a communication interface, which is used to establish a communication link with the reference device. The communication interface can be a wired communication interface or a wireless communication structure. This embodiment does not limit this. For example, there are many types of communication interfaces that can be used between the host computer and the reference device. Wired communication interfaces include common Ethernet ports, serial communication interfaces such as RS-485 or RS-232, and USB interfaces. These are connected by physical cables and have the characteristics of high reliability and strong anti-interference ability. Wireless communication structures include Wi-Fi, Bluetooth, ZigBee, and proprietary wireless protocols for industrial environments. These do not require wiring, provide greater flexibility in device layout, and are suitable for moving reference devices or industrial sites where wiring is difficult.

[0132] Among them, the control equipment is used to control the processing station to process the reference part and record the working parameters of the control equipment. In actual production, the host computer can read the working parameters of the PLC (control equipment), and thus determine the working status of the processing station and the time node of the work, thereby understanding the various parameters of the processing.

[0133] In practical implementation, the reference component records the tensile force data of the testing department. The shape of the reference component can be manufactured to match the product, for example, it can be made into the shape of a long block after the battery cell is wound and shaped, and then a thin metal sheet similar to an electrode tab is fixed on the block. Figure 2 as well as Figure 3 As shown, in a specific scenario, for example, a reference component in the form of a battery cell is placed in a welding station for ultrasonic welding. The sensor built into the reference component can sense the external force received by the tab (test section) and record it.

[0134] Furthermore, the host computer filters the tensile data to identify tensile anomalies. By filtering the tensile data, it can identify tensile or compressive forces that may damage the product. If destructive tensile or compressive forces are found, it is considered that there is an anomaly in the production process. The abnormal production process is regarded as a tensile anomaly point. When an anomaly is found, the working parameters of the control equipment are combined to find the working parameters of the PLC at the tensile anomaly point and generate an early warning result.

[0135] It is important to emphasize that the tensile force data in this solution represents either tensile or compressive force. This is because force has direction; a positive tensile force represents tension in the conventional sense, while a negative tensile force represents compressive force in the conventional sense. In this embodiment, the tensile force actually represents the force experienced by the testing part (electrode). In actual production, the ultrasonic welding process actually involves... Figure 2 as well as Figure 3 The process of welding the test section (electrode) to the welding object (adapter piece) involves using a reference component to measure the stress on the test section (electrode) during the welding process.

[0136] It should be noted that the reference component records the tensile force it experiences during processing. This data is then processed by a host computer to determine if any processing abnormalities exist, ensuring the rationality of various control parameters during processing. By simulating actual product processing, problems in the processing process are identified from the product's perspective. Tensile force data generated on the product during production is read and monitored to determine if the tensile force exceeds limits. This assesses the risk of product cracking during production, improving the accuracy and comprehensiveness of crack risk detection.

[0137] In some embodiments, when the identification acquisition device recognizes the identification information of the reference part, the control processing station processes the reference part and records the working parameters of the control device, including: when the identification acquisition device recognizes the identification information of the reference part, controlling the processing station to process the reference part and generating a working timestamp corresponding to the processing step, wherein the processing step corresponds to the working condition information; recording the working condition information of the processing station and the working timestamp corresponding to the working condition information; and generating the working parameters of the control device based on the working condition information of the processing station and the working timestamp corresponding to the working condition information.

[0138] It should be noted that the identification acquisition device can be a barcode scanner or an image acquisition device. It is realized by acquiring identification information set on the reference piece or identifying the reference piece. The identification information can be a barcode, QR code or other identification image, or a triggering device such as an electronic chip.

[0139] The system automatically activates the control equipment via a trigger signal generated by the identification information. This trigger signal then controls the processing station to start a test cycle, which involves processing the reference part and acquiring the working status of each station during processing. The resulting data is used to generate the operating parameters of the control equipment. The trigger signal, generated by identifying the identification information, creates a time reference point. This time reference point serves as a time synchronization point between the reference part and the control equipment. For example, when the identification information is detected, a time reference point is generated. The timestamps of both devices are generated using this time reference point as the starting point. Based on this time reference point, a working timestamp corresponding to the working condition information is generated. This shared time reference point ensures that the timestamps of the host computer and the reference part remain consistent. Both the working timestamp and the time stamp are time scales generated based on the time reference point, used to synchronize the working condition information and the tensile force data borne by the reference part.

[0140] It should be noted that filtering tensile data can only help determine if there is a problem. Locating the anomalies in tensile data is the only way to solve the problem. By using timestamps to link the working conditions of the processing station with the changes in tensile data, the correlation between anomalies in tensile data and working conditions is realized. This allows us to identify which production processes caused the anomalies and improves the efficiency of anomaly handling.

[0141] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A tab cracking early warning system, characterized in that, The system includes: a host computer, a control device, and a reference component. The host computer is communicatively connected to the control device and has a communication interface for establishing a communication link with the reference component. The reference component has a testing unit. The system includes: The control device is used to control the processing station to process the reference part and record the working parameters of the control device; The reference component is used to record the tensile force data of the test section; The host computer is used to acquire the operating parameters of the control device and the tensile force data of the test unit; The host computer is used to filter the tensile data, identify tensile anomalies, and determine early warning results based on the operating parameters of the control device and the tensile anomalies. The host computer is used to query the operating parameters of the control device based on the tensile anomaly point to obtain the operating condition information corresponding to the tensile anomaly point. The timestamp corresponding to the tensile anomaly point corresponds one-to-one with the working timestamp corresponding to the operating condition information.

2. The system as described in claim 1, characterized in that, The control equipment also includes: an identification acquisition device; The identification acquisition device is used to detect the identification information of the reference piece and generate a trigger signal based on the identification information; The control device is used to generate a time reference point in response to the trigger signal; The control device is used to record the working condition information of the processing station and generate a working timestamp corresponding to the working condition information based on the time reference point. The control device is used to generate operating parameters for the control device based on the operating condition information of the processing station and the corresponding working timestamp.

3. The system as described in claim 1, characterized in that, The reference component further includes a sensor, and the test unit is fixed to the sensor; The sensor is used to detect the tensile force data applied to the test section.

4. The system as described in claim 3, characterized in that, The sensor is a triaxial force sensor, and the reference component also includes a controller. The sensor is used to detect the orthogonal axial force components that the test part is subjected to. The orthogonal axial force components are characterized as three axial components that are orthogonal to each other in a spatial rectangular coordinate system. The controller is used to synthesize the orthogonal axial force components into a spatial resultant force by torque synthesis, and to generate tensile data of the test section based on the orthogonal axial force components and the spatial resultant force.

5. The system as described in claim 3, characterized in that, The sensor is a triaxial force sensor; The sensor is used to detect the orthogonal axial force components that the test part is subjected to. The orthogonal axial force components are characterized as three axial components that are orthogonal to each other in a spatial rectangular coordinate system. The host computer is used to synthesize the orthogonal axial force components into a spatial resultant force by torque synthesis, and to generate tensile data of the test unit based on the orthogonal axial force components and the spatial resultant force.

6. The system as described in claim 1, characterized in that, The communication interface includes: a wireless communication interface; The wireless communication interface is used to establish a wireless communication link with the reference device.

7. The system as described in claim 1, characterized in that, The communication interface further includes: a wired connection interface; The wired connection interface is used to establish a wired communication link when the reference part is processed at the processing station.

8. A method for early warning of electrode cracking, characterized in that, The method is applied to a host computer, which is communicatively connected to a control device. The control device is used to control the processing station. The host computer is equipped with a communication interface for establishing a communication link with a reference component. The reference component is equipped with a testing section for collecting tensile force data of the reference component at the testing section. The tab cracking early warning method includes: Obtain the operating parameters of the control device; The tensile force data is filtered to identify points of tensile force anomalies; The warning result is determined based on the operating parameters of the control device and the abnormal tension points; The step of determining the early warning result based on the operating parameters of the control device and the abnormal tension point includes: The working condition information of the processing station and the corresponding working timestamp are determined based on the working parameters of the control equipment. Determine the timestamp corresponding to the tensile anomaly point based on the tensile anomaly point; The mapping between the tensile anomaly point and the working time stamp corresponding to the processing station is determined by matching the timestamp corresponding to the tensile anomaly point with the working time stamp of the processing station. The warning result is determined based on the mapping between the tension anomaly point and the working condition information.

9. The method as described in claim 8, characterized in that, The step of filtering the tensile data to identify tensile anomalies includes: The tensile data is filtered, and time points in the tensile data where the tensile force is not within the preset tensile force range are identified as tensile anomaly points; The preset tensile force range is determined by the material yield limit of the test part.

10. The method as described in claim 8, characterized in that, The step of determining the early warning result based on the mapping between the tensile anomaly point and the working condition information includes: The machining station corresponding to the tensile anomaly point and the anomaly type corresponding to the tensile anomaly point are determined based on the mapping between the tensile anomaly point and the working condition information. An early warning result is generated based on the tensile force data of the tensile anomaly point, the processing station corresponding to the tensile anomaly point, and the anomaly type corresponding to the tensile anomaly point.

11. The method as described in claim 8, characterized in that, The testing unit includes a triaxial force sensor and a testing component. The testing component is fixed on the triaxial force sensor. The machining station is used to machine the testing component. The tensile force data of the reference piece in the testing unit is acquired through the following methods: Obtain the orthogonal axial force components of the test component, which are characterized as three mutually orthogonal axial components in a spatial rectangular coordinate system; The orthogonal axial force components are combined to generate a spatial resultant force, and the tensile force data of the test section is generated based on the orthogonal axial force components and the spatial resultant force.

12. The method as described in claim 8, characterized in that, The step of determining the early warning result based on the operating parameters of the control device and the abnormal tension point includes: Based on the operating parameters of the control device and the tension anomaly point, determine at least one of the following: tension data of the tension anomaly point, the processing station corresponding to the tension anomaly point, and the anomaly type corresponding to the tension anomaly point; The corresponding production line information is determined based on the processing station corresponding to the tensile anomaly point. Display at least one of the following: production line information, tensile data at tensile anomaly points, processing station corresponding to tensile anomaly points, and anomaly type corresponding to tensile anomaly points.

13. A method for early warning of electrode cracking, characterized in that, The method is applied to a control device, which is communicatively connected to a host computer and a processing station. The host computer is equipped with a communication interface for establishing a communication link with a reference part. The reference part is equipped with a testing section for collecting tensile force data of the reference part at the testing section. The control device is equipped with an identification and acquisition device. The method includes: When the identification acquisition device recognizes the identification information of the reference part, it controls the processing station to process the reference part and records the working parameters of the control equipment. The operating parameters of the control device are sent to the host computer, so that the host computer can generate an early warning result based on the operating parameters of the control device and the tensile data of the test section.

14. The method as described in claim 13, characterized in that, When the identification acquisition device recognizes the identification information of the reference part, the process involves controlling the processing station to process the reference part and recording the operating parameters of the control equipment, including: When the identification acquisition device recognizes the identification information of the reference part, it controls the processing station to process the reference part and generate a working timestamp corresponding to the processing step, wherein the processing step corresponds to the working condition information; Record the working condition information of the processing station and the corresponding working timestamp; The operating parameters of the control equipment are generated based on the operating condition information of the processing station and the corresponding working timestamp.

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