Welding process optimization method and device for secondary battery

Abstract

The invention relates to a method and a device for optimizing a welding process of a secondary battery. The welding process optimization method of the secondary battery according to one embodiment of the present disclosure comprises the steps of: setting an electrode flag height; modeling a winding shape and a flag shape by using the set flag height; based on the modeled shape, the flag overlapping degree is visualized; modeling a laser output value according to an overlap level of a flag part on the basis of the visualized overlap degree data, and making the modeled laser output value into a database; and the flag height is measured in real time in the welding process, and the optimal laser output is set according to the information of the database.

Description

Technical Field

[0001] This disclosure relates to a method and apparatus for optimizing the welding process of secondary batteries. Background Technology

[0002] Due to their rechargeability, rechargeable batteries are widely used in electric vehicles, portable electronic devices, energy storage devices (ESS), and many other fields.

[0003] In the manufacturing process of secondary batteries, a welding process is required to bond the electrodes to the current collector (CC). Since the welding quality has a significant impact on the performance and safety of the battery, the design of welding parameters is very important.

[0004] In the past, in order to bond the electrode foil to the current collector, a grooving process was performed to cut the uncoated portion of the electrode into a flag shape, which was then bent at a right angle and wound.

[0005] In this case, if inappropriate welding parameters are used during the formation and winding of the flag, quality problems such as failure to weld between the electrode foil and the current collector or damage to the separator may occur, leading to a decrease in battery efficiency and causing safety hazards due to short circuits.

[0006] In addition, the degree of welding of the electrode foil will vary due to the different overlap of the flags. Therefore, if the overlap level cannot be accurately determined in advance, it will be difficult to set the welding parameters.

[0007] Furthermore, in the manufacturing process, the height or overlap of the electrodes can vary with environmental conditions or material states. However, existing processes struggle to adjust welding parameters in real time to reflect these changes, leading to increased defect rates and decreased battery performance and lifespan. Summary of the Invention

[0008] (a) Technical problems to be solved

[0009] According to one aspect of this disclosure, a method and apparatus for optimizing the welding process of a secondary battery can be provided.

[0010] According to one aspect of this disclosure, a method and apparatus for optimizing the welding process of a secondary battery can be provided, which sets optimal welding parameters by simulating the overlap based on the shape of the flag and measuring the height of the flag in real time.

[0011] The welding process optimization method and apparatus for secondary batteries disclosed herein can be widely applied to electric vehicles, battery charging stations, and other green technology fields such as solar power generation and wind power generation that utilize batteries.

[0012] Furthermore, the welding process optimization method and apparatus for secondary batteries disclosed herein can be used in eco-friendly electric vehicles, hybrid vehicles, and the like to prevent climate change by suppressing air pollution and greenhouse gas emissions.

[0013] (II) Technical Solution

[0014] A welding process optimization method for a secondary battery according to an embodiment of the present disclosure may include the following steps: (a) setting the height of the electrode flag; (b) modeling the winding shape and the flag shape using the set flag height; (c) visualizing the flag overlap based on the modeled shape; (d) modeling and databaseling the laser output value according to the overlap level of the flag based on the visualized overlap data; and (e) measuring the flag height in real time during the welding process and setting the optimal laser output using the information in the database.

[0015] According to one embodiment of this disclosure, in the winding shape modeling step of step (b), the width and height of the flag portion can be set in an arithmetic sequence so that the size of the flag portion gradually changes during winding.

[0016] According to one embodiment of this disclosure, in the winding shape modeling step of step (b), the winding angle of the flag can be calculated by the Archimedes spiral equation, and a rotation matrix can be applied to each flag to simulate the winding shape.

[0017] According to one embodiment of this disclosure, in the visualization step of step (c), the overlap of each flag can be projected onto the image plane so that it is displayed with different pixel values ​​according to the degree of overlap.

[0018] According to one embodiment of this disclosure, in the visualization step of step (c), the overlap level can be displayed in different colors or shades to distinguish the degree of overlap of the flags.

[0019] According to one embodiment of this disclosure, the database in step (d) may contain data that maps the overlap level of the flag height to the optimal laser output value.

[0020] According to one embodiment of this disclosure, in the welding process of step (e), the laser output value can be dynamically adjusted according to the real-time measured height of the flag.

[0021] According to one embodiment of this disclosure, according to steps (d) and (e), a welding process can be performed using a laser output value preset according to the overlap level of the flag to achieve optimal bonding between the electrode and the current collector (CC).

[0022] A welding process optimization apparatus for a secondary battery according to another embodiment of the present disclosure may include: a flag height setting unit for setting a flag height; a modeling unit for modeling a winding shape and a flag shape using the set flag height; a visualization unit for visually displaying the flag overlap based on the modeled shape; a data storage unit for modeling and database-storing laser output values ​​based on the visualized overlap data according to the flag overlap level; and a control unit for measuring the flag height in real time during the welding process and controlling the laser output based on the information in the database.

[0023] According to one embodiment of the present disclosure, the modeling unit can set the width and height of the flag portion in an arithmetic sequence, so that the size of the flag portion gradually changes during winding.

[0024] According to one embodiment of this disclosure, the modeling unit can apply the Archimedes spiral equation to calculate the winding angle of the flag and apply a rotation matrix to each flag to simulate the winding shape.

[0025] According to one embodiment of the present disclosure, the visualization unit can project the overlap of each flag onto an image plane, so that it is displayed with different pixel values ​​according to the degree of overlap.

[0026] According to one embodiment of this disclosure, the visualization section can display the overlap level in different colors or shades to distinguish the degree of overlap of the flag sections.

[0027] According to one embodiment of this disclosure, the data storage unit may contain data that maps the overlap level of the flag height to an optimal laser output value.

[0028] According to one embodiment of the present disclosure, the control unit may include a feedback control system that dynamically adjusts the laser output value based on the flag height measured in real time during the welding process.

[0029] According to one embodiment of this disclosure, the laser output value of the data storage unit can be used for a welding process to achieve optimal bonding between the electrode and the current collector.

[0030] (III) Beneficial Effects

[0031] According to one embodiment of this disclosure, welding quality can be improved by optimizing the welding process of secondary batteries.

[0032] According to one embodiment of this disclosure, the height of the flag and the level of overlap can be determined and a matching laser output value can be set, thereby reducing welding defects and improving the performance and lifespan of the secondary battery. Attached Figure Description

[0033] Figure 1 This is a flowchart illustrating a welding process optimization method for a secondary battery according to an embodiment of the present disclosure.

[0034] Figure 2 This is a diagram illustrating an example of a welding process optimization apparatus for a secondary battery according to an embodiment of the present disclosure.

[0035] Figure 3 This is a reference for designing the shape of a flag according to an embodiment of the present disclosure.

[0036] Figure 4 This is a diagram illustrating a winding shape modeling based on the Archimedes spiral equation according to an embodiment of the present disclosure.

[0037] Figure 5 This is a diagram illustrating the process of a flag shape reflecting a winding state based on the Archimedes spiral equation, according to an embodiment of the present disclosure.

[0038] Figure 6 This is a diagram that visualizes the overlap of the flags according to an embodiment of the present disclosure.

[0039] Figure 7 This is a schematic diagram illustrating the process of modeling the optimal laser output value according to an embodiment of the present disclosure.

[0040] Figure 8 This is a schematic diagram of a process for optimizing a laser welding process based on real-time measurement of the height of the uncoated portion, according to an embodiment of the present disclosure.

[0041] Figure 9 This is a diagram of an electric vehicle illustrating a welding process optimization method and apparatus for a secondary battery according to an embodiment of the present disclosure. Detailed Implementation

[0042] The present disclosure will now be described in detail with reference to the accompanying drawings. However, this is merely exemplary and is not limited to the specific embodiments described herein.

[0043] Although ordinal numbers such as first, second, etc., are used to describe various elements, components, and / or parts, these elements, components, and / or parts are not limited by these terms. These terms are used only to distinguish one element, component, or part from another element, component, or part. Therefore, within the scope of the technical concept of this disclosure, the first element, first component, or first part mentioned below may also be a second element, second component, or second part.

[0044] The terminology used in this specification is for illustrative purposes only and is not intended to limit this disclosure. In this specification, the singular form includes the plural form unless otherwise specified herein. The terms "comprises" and / or "made of" as used in this specification do not exclude the presence or addition of one or more other components, steps, operations, and / or elements besides those mentioned.

[0045] Unless otherwise defined, all terms used in this specification (including technical and scientific terms) are to be used in the sense that would be commonly understood by one of ordinary skill in the art to which this disclosure pertains. Furthermore, unless explicitly defined, terms as defined in commonly used dictionaries should not be idealized or over-interpreted.

[0046] Figure 1 This is a flowchart illustrating a welding process optimization method for a secondary battery according to an embodiment of the present disclosure. Figure 2 This is a diagram illustrating an example of a welding process optimization apparatus for a secondary battery according to an embodiment of the present disclosure.

[0047] See Figure 1 A welding process optimization method for a secondary battery according to an embodiment of the present disclosure may include the following steps: (a) setting the height of the electrode flag 30 (S810); (b) modeling the winding shape and the shape of the flag 30 using the set flag height (S820); (c) visualizing the flag overlap based on the modeled shape (S830); (d) modeling and databasering the laser output value based on the visualized overlap data according to the overlap level of the flag 30 (S840); and (e) measuring the height of the flag 30 in real time during the welding process and setting the optimal laser output using the information in the database (S850).

[0048] In this disclosure, the welding process for secondary batteries can be applied to various types or shapes, such as prismatic and cylindrical secondary batteries.

[0049] This disclosure aims to improve welding quality and increase production efficiency by optimizing the welding process of secondary batteries. According to one embodiment, the height and overlap level of the flag section 30 can be determined and a matching laser output value can be set, thereby reducing welding defects and improving the performance and lifespan of the secondary battery.

[0050] According to an embodiment of the present disclosure, the welding process optimization method for a secondary battery firstly (a) sets the height of the electrode flag 30 (S810).

[0051] According to one embodiment of this disclosure, the height of the flag portion 30 is set to achieve optimal welding between the electrode and the current collector (CC). The flag portion 30, as the uncoated portion 20 of the electrode, is designed to stably bond with the current collector. An electrode active material 10 is coated on a metal foil, and the edge region of the uncoated electrode active material 10 can become the uncoated portion 20 of the electrode. The flag portion 30 can be formed in the uncoated portion 20 of the electrode by a laser grooving process.

[0052] The flag portion 30 can be in the shape of a quadrilateral or similar shape, so as to roll up the uncoated portion (uncoated metal foil) 20 of the electrode in a right-angle folded state. The shape of the flag portion 30 can be a rectangle, square, rounded quadrilateral, S-shaped quadrilateral, parallelogram, trapezoid, triangle or other shapes according to the designer's intention.

[0053] According to one embodiment of the present disclosure, the height of the flag 30 affects the welding strength and current transmission efficiency. Therefore, the optimal overlap conditions are set by presetting the height, and a reference value is provided for subsequent overlap analysis and simulation.

[0054] According to one embodiment of the present disclosure, (b) the winding shape and the shape of the flag 30 are modeled using the set height of the flag 30 (S820).

[0055] According to one embodiment of this disclosure, the winding shape includes an increase in the total winding angle and radius of the electrodes. During this process, the winding shape is simulated using the Archimedes' spiral equation, and the winding position and angle of each flag 30 can be calculated using a rotation matrix. This allows for the prediction of the physical arrangement and height of the overlapping flags 30, thereby enabling accurate visualization in the next step.

[0056] According to one embodiment of the present disclosure, in the winding shape modeling step (S820) of step (b), the width and height of the flag portion 30 can be set in an arithmetic sequence so that the size of the flag portion 30 gradually changes during winding.

[0057] Figure 3 This is a reference for the design of the shape of the flag 30 according to an embodiment of the present disclosure.

[0058] As shown in the figure, a cylindrical battery (or prismatic battery) is a structure that is wound from the inner radial direction to the outer diameter direction, with the radius gradually increasing. Therefore, the width of the flag section 30 (w) s : Starting flag width, w e The width of the end flag section can also gradually increase, or increase first and then decrease, or be constructed with a constant width. The height h of the flag section 30 can also gradually increase, or increase first and then decrease, or be constructed with a constant height.

[0059] This is to design the size of the flag 30 to gradually change during the winding process, in order to minimize the overlap problems and flag damage that may occur during welding, and to maintain a constant overlap by gradually adjusting the width and height of the flag 30, which can optimize the current transmission path and improve the welding quality.

[0060] According to one embodiment of this disclosure, the width w of the flag portion 30 can be set to increase in the form of an arithmetic sequence, as shown in the following formula.

[0061]

[0062] Therefore, as the flag is rolled up, its width increases towards the outer edge. If the width is constant, the common difference of the arithmetic sequence can be defined as 0. Wherein, Let K be the width of the k-th flag, and K be the total number of flags. Width tolerance is defined as .

[0063] According to one embodiment of this disclosure, the height h of the flag section 30 can also be set in an arithmetic sequence, such that the height gradually changes according to the winding angle. If the height of the flag section 30 changes according to the winding direction, the overlapping state can remain constant, and the height of each flag section is set in the following arithmetic sequence.

[0064]

[0065] If the height is constant, the common difference of an arithmetic sequence is defined as 0. Wherein, Let K be the height of the k-th flag unit, and K be the total number of flag units. For height tolerance, it is defined as .

[0066] The electrodes of a cylindrical battery can exist in intervals where the flag is present and in intervals where the flag is not present. To calculate the total length S of the intervals where the flag is present, an arithmetic series summation formula can be used.

[0067]

[0068] The width and height of the flag section 30, set in an arithmetic sequence, help the size of the flag section 30 to change gradually during the winding process, while maintaining a constant degree of overlap and bonding strength with the current collector.

[0069] As a specific embodiment of this disclosure, the width w1 of the starting flag portion 30 can be set to 0.1 mm, and the tolerance d w The width of each flag section 30 is set to 0.05mm, so that the width increases by 0.05mm in increments as the flag is wound. Simultaneously, the initial flag section height h1 is set to 0.1mm, with a tolerance d. h The setting is 0.02mm, which allows the height to gradually increase. With this setting, the size of the flag section 30 gradually increases in the winding direction, forming a flag section 30 shape that widens towards the outer edge. This ensures a constant overlap during welding and allows for welding with optimal laser output.

[0070] Therefore, according to one embodiment of this disclosure, the size of the flag portion 30 gradually increases, ensuring uniform overlap of the flag portions 30 during winding and preventing excessive or insufficient overlap, thereby ensuring a stable connection between the electrode and the current collector. This can improve welding strength, reduce problems of incomplete welding or flag portion damage, and extend the life of the secondary battery.

[0071] According to one embodiment of this disclosure, the winding shape modeling step (S820) in step (b) can calculate the winding angle of the flag section using the Archimedes' spiral equation and apply a rotation matrix to each flag section to simulate the winding shape. By using the Archimedes' spiral equation, the angle and position of the flag section arrangement during the secondary battery winding process can be calculated, thereby modeling the winding state of the flag section and confirming the overlap conditions required to maintain optimal welding quality.

[0072] Figure 4 This is a diagram illustrating a winding shape modeling based on the Archimedes spiral equation according to an embodiment of the present disclosure.

[0073] like Figure 4 As shown, the Archimedes spiral equation is used to calculate the radius of the flag at each winding position, and the equation is expressed as follows.

[0074]

[0075] Where r is the radius, denoted as the winding angle, 'a' as the increase in radius per rotation, and 'b' as the initial radius value. 'a' and 'b' represent information about the winding shape.

[0076] Here, the winding angle of each flag section It can be calculated using the following formula.

[0077] The flag section, whose width increases at constant intervals, has a circular, coiled shape. Therefore, the coiling angle of each flag section can be calculated using the Archimedes' spiral equation and the sum of the flag section lengths.

[0078] Assume the sum of the widths of the first to the kth flags This is equivalent to applying the helical equation at the winding angle. The result of the integration can be expressed as follows.

[0079]

[0080]

[0081] Among them, due to >0, and Since it is in the form of a quadratic equation, it can be obtained using the quadratic formula. The solution.

[0082]

[0083] The position and orientation of each flag unit 30 can be specified using a rotation matrix. Figure 5 This is a diagram illustrating the process of a flag shape reflecting a winding state based on the Archimedes spiral equation, according to an embodiment of the present disclosure.

[0084] like Figure 5 As shown, according to the winding angle Find the coordinates of each point where the flag part 30 will be located, and apply the rotation matrix to determine the final position.

[0085] Using the winding angle corresponding to the kth flag section 30 The coordinates of a single flag 30 shape can be represented as the coordinates after winding.

[0086] First, the four points X of the flag section 30 are represented with the origin as the center, and are respectively designated as point 1, point 2, point 3, and point 4. Then, the four points X' of the flag section 30, which is wound around a spiral, are respectively designated as point 1', point 2', point 3', and point 4'.

[0087] Calculate the corresponding equation using Archimedes' spiral. The coordinates of point 1' ).

[0088]

[0089]

[0090]

[0091] The coordinates of point 2' are ( The coordinates of point 1' of the adjacent (k+1)th flag 30 are the same, so the calculation is as follows.

[0092]

[0093]

[0094]

[0095] The rotation angle of the flag 30 is calculated using points 1' and 2'. as follows.

[0096]

[0097] By the rotation angle of the flag 30 ψ Calculate the rotation matrix R in a two-dimensional plane.

[0098]

[0099] In order to reflect the basic shape of the flag part 30 located at the origin as a spiral shape, the four vertices are rotated using a rotation matrix and translated to the coordinates of point 1'.

[0100]

[0101] As a specific embodiment of the present invention, the arrangement angle of the flag section 30 can be calculated using the Archimedean spiral equation with an initial radius b of 1 mm and a growth rate a of 0.1 mm. For example, based on the total length of the flag section 30... The winding angle of the flag section 30 is determined, and a rotation matrix is ​​applied based on the angle to set the coordinates of each flag section 30. Thus, as winding proceeds, the flag sections 30 can be arranged at constant angles, and the overlap level of the flag sections 30 can remain uniform.

[0102] Therefore, according to an embodiment of the present invention, by using the Archimedes spiral equation, the arrangement angle of the flag section 30 can be accurately calculated, thereby maintaining a constant interval and overlap during winding.

[0103] Furthermore, by applying a rotation matrix, the flags 30 overlap at a constant angle during winding, thereby maintaining constant welding strength through a uniform winding structure and achieving consistent bonding between the electrode and the current collector.

[0104] According to one embodiment of this disclosure, (c) the overlap of the flag portion is visualized based on the modeled shape (S830).

[0105] According to one embodiment of this disclosure, the overlap of the flag portions is visualized based on the modeled coil shape and the shape of the flag portion 30. By projecting the overlap onto an image plane and displaying the degree of overlap of each flag portion 30 in terms of pixel values, color, brightness, etc., the level of overlap can be intuitively understood. For example, more overlap is assigned a higher pixel value, and less overlap is assigned a lower value, thereby visualizing the overlap. This data can serve as the basis for subsequent laser output value modeling.

[0106] Furthermore, according to one embodiment of this disclosure, in the visualization step (S830) of step (c), the overlap of each flag can be projected onto the image plane so that it is displayed with different pixel values ​​according to the degree of overlap.

[0107] This is achieved by projecting the overlap of the flags onto an image plane and visualizing it as pixel values, so as to intuitively grasp the degree of overlap. By assigning different pixel values ​​according to the level of overlap, the degree of overlap can be effectively monitored.

[0108] According to one embodiment of this disclosure, the overlap of each flag portion can be projected onto a two-dimensional image plane. The pixel values ​​change depending on the position and degree of overlap of each flag portion 30, thereby visually displaying the degree of overlap of the flag portions 30.

[0109] According to one embodiment of this disclosure, the pixel values ​​of the image plane are set differently based on the degree of overlap of the flag portions 30. For example, the higher the degree of overlap, the higher the pixel value, thereby allowing the overlap level to be visually confirmed.

[0110] As a specific embodiment of this disclosure, the degree of overlap can be displayed by incrementing the pixel value at the corresponding position by 1 each time the flags 30 overlap. Thus, areas with high overlap have high pixel values, while areas with low overlap have low pixel values.

[0111] Therefore, according to one embodiment of this disclosure, the overlap level can be conveniently visualized by pixel values, and if the overlap is uneven, it can be immediately identified and necessary process adjustments can be performed to improve welding quality.

[0112] According to one embodiment of this disclosure, in the visualization step (S830) of step (c), the overlap level can be displayed in different colors or shades to distinguish the degree of overlap of the flag portions 30.

[0113] This visualizes the level of overlap of the flag section through color or brightness differences, making it easier to distinguish the degree of overlap. By displaying different colors or brightness according to the level of overlap, the degree of overlap of the flag section can be quickly grasped.

[0114] For example, areas with low overlap can be displayed in a light color, while areas with high overlap can be set to a dark color. Five levels of brightness can be set, with level 1 indicating low overlap and level 5 indicating maximum overlap.

[0115] Therefore, according to one embodiment of this disclosure, the degree of overlap can be more clearly distinguished by color or brightness difference, making it easier to detect poor overlap and visually confirm uneven overlap.

[0116] According to one embodiment of this disclosure, (d) the laser output value based on the visualized overlap data is modeled and database-ized according to the overlap level of the flag 30 (S840).

[0117] According to one embodiment of this disclosure, the optimal laser output value based on the overlap level of the flag 30 is modeled by analyzing visualized overlap data. Since the required laser output value varies depending on the overlap level, each overlap level is mapped to an optimal laser output value and databased. For example, a high overlap range may require a high output value, while a low overlap range may require a low output value. By acquiring this data in advance, the optimal laser output value can be quickly referenced from the database during the welding process.

[0118] According to one embodiment of this disclosure, the database in step (d) (S840) may contain data that maps the overlap level of the flag height 30 to the optimal laser output value.

[0119] This involves mapping and databaseling the overlap level of the flag section 30 and the optimal laser output value that corresponds to it. By storing the optimal laser output value that matches the overlap level of the flag section 30 in the database, it can be referenced in real time during the welding process, thereby optimizing the welding quality.

[0120] According to one embodiment of this disclosure, the height of the flag 30 is one of the main variables affecting the degree of overlap. The overlap level is calculated based on this. If the overlap level is below a predetermined value, it may lead to poor welding. Therefore, to prevent this situation, the overlap level data based on the height of the flag 30 is stored in the database.

[0121] According to one embodiment of this disclosure, an optimal laser output value is pre-set for each overlap level and stored in a database. During the welding process, the height of the flag section 30 is measured in real time to determine the overlap level, and the pre-mapped optimal laser output value is applied to the welding, thereby improving quality.

[0122] According to one embodiment of this disclosure, a database is systematically constructed by organizing mapping data including flag height, overlap level, and laser output value. It is designed to be referenced in real time during the process, and the user can expand or modify the database according to welding conditions.

[0123] As a specific embodiment of this disclosure, for example, when the height of the flag 30 is 1mm, 2mm, or 3mm, the overlap level is different, and a database can be constructed to set the optimal laser output value to 10W, 12W, or 15W respectively. During the welding process, if the measured height of the flag 30 is 2mm, the overlap level and the optimal laser output value (12W) are automatically retrieved from the database and applied to maintain the best welding quality.

[0124] Therefore, according to one embodiment of this disclosure, by mapping the optimal laser output value based on the height of the flag 30 and the overlap level, it can be referenced in real time during the process, thereby ensuring consistent welding quality.

[0125] Furthermore, the database allows for the rapid retrieval of required laser output values, thereby shortening process time and reducing defect rates. Additionally, the mapping data enables adjustments to welding conditions, facilitating quality management and preventing welding defects.

[0126] According to one embodiment of this disclosure, (e) the height of the flag 30 is measured in real time during the welding process, and the optimal laser output is set using information from the database (S850).

[0127] According to one embodiment of this disclosure, the height of the flag section 30 is measured in real time during the welding process, and the optimal laser output value is set with reference to the database information from the previous step. At this time, a feedback control system 600 that dynamically adjusts the laser output based on the height of the flag section 30 in real time can be used to stabilize the welding quality and reduce the defect rate. This step improves welding stability by reflecting the height of the flag section 30 and the overlap level in real time during the actual welding process.

[0128] According to one embodiment of this disclosure, the welding process in step (e) (S850) may include a feedback control system 600, which dynamically adjusts the laser output value based on the real-time measured height of the flag 30.

[0129] This improves welding quality and reduces defects by monitoring the height of the flag section 30 in real time and responding immediately to any changes that may occur during the welding process.

[0130] According to one embodiment of this disclosure, the height of the flag section 30 is measured in real time during the welding process, and the overlap level is assessed based on this. The height of the flag section 30 has a significant impact on the welding quality, therefore, real-time measurement reflects changes in height immediately.

[0131] According to one embodiment of the present disclosure, the feedback control system 600 dynamically adjusts the optimal laser output value based on the measured height of the flag 30, and automatically adjusts the output value required for the welding process based on real-time data, thereby maintaining consistent welding quality.

[0132] According to one embodiment of this disclosure, the output can be automatically adjusted during the welding process by setting the overlap level based on the height of the flag 30 and the laser output value used to correct the overlap level.

[0133] As a specific embodiment of this disclosure, a feedback control system 600 can be implemented to dynamically adjust the laser output value based on a sensor that detects the height of the flag section 30 in real time. For example, if the height of the flag section 30 is higher than a reference value, the overlap increases, so the laser output value can be automatically increased to ensure sufficient welding. Conversely, if the height of the flag section 30 is lowered, the laser output can be reduced to prevent over-welding that could damage the diaphragm.

[0134] Therefore, according to one embodiment of this disclosure, real-time feedback control can respond instantly to changes in the height of the flag section 30, maintain constant welding quality, and prevent over- or under-welding by adjusting the laser output in real time, thereby significantly reducing the welding defect rate.

[0135] In addition, the feedback control system 600 can monitor and adjust the welding process in real time, improving the stability and efficiency of the process.

[0136] Thus, according to one embodiment of the present disclosure, the feedback control system 600 dynamically adjusts the laser output value based on the height of the flag 30 to quickly respond to changes that may occur in the welding process, thereby maintaining consistent quality and improving process stability.

[0137] According to one embodiment of this disclosure, a welding process can be performed using a laser output value preset according to the overlap level of the flag 30, based on steps (d) and (e), to achieve optimal bonding between the electrode and the current collector (CC).

[0138] This is to optimize the bonding between the electrode and the current collector (CC) by using a preset laser output value for the welding process. Therefore, the preset optimal laser output value is applied according to the overlap level of the flag 30 to ensure consistent bonding quality and improve welding process efficiency.

[0139] The performance and stability of a secondary battery are highly dependent on the bonding quality between the electrodes and the current collector. Therefore, optimizing the output value based on the overlap level during the welding process is to ensure a strong bond between the electrodes and the current collector.

[0140] According to one embodiment of this disclosure, laser output values ​​preset in the pre-modeling step based on the height of the flag 30 and the overlap level are applied to the welding process, thereby consistently maintaining welding quality. The optimal output values ​​stored in the database are then called up during the process, and welding is flexibly performed according to the overlap level.

[0141] That is, referring to the database information generated in step (d), and applying the output values ​​that match the flag height 30 and overlap level measured in real time in step (e), optimal welding is performed. This optimizes the overlap state throughout the welding process, maintaining high-quality electrode bonding.

[0142] As a specific embodiment of this disclosure, a database of laser output values ​​preset according to the bonding area between the electrode and the current collector can be pre-programmed, and then only the corresponding values ​​can be called and applied quickly during the welding process. For example, when the overlap level is high, a strong bonding with the current collector is required, so the output value is increased; when the overlap level is low, the output value is decreased to ensure an appropriate welding depth and prevent damage to the diaphragm.

[0143] Thus, according to an embodiment of the secondary battery welding process optimization method of this disclosure, in the secondary battery manufacturing process where the winding shape and the shape of the flag 30 are pre-modeled, the height of the flag 30 can be set to a constant value, and the width and height of each flag 30 are designed to increase in an arithmetic progression. The winding angle is calculated using the Archimedes' spiral equation, and the modeled flag 30 is visualized and its overlap is displayed in color on an image plane. Based on the visualized overlap data, the laser output value is set according to the overlap level of the flag 30 and stored in a database. Subsequently, the height of the flag 30 is measured in real time during the welding process, and the laser output is automatically adjusted for welding based on the database information.

[0144] Therefore, according to one embodiment of this disclosure, by accurately analyzing the overlap level of the flag section 30 and setting the corresponding optimal laser output value, problems such as unwelded sections or diaphragm damage can be minimized, thereby improving welding quality. Furthermore, by quickly setting welding parameters using a preset database and automating the welding process through real-time control, production efficiency is significantly improved. Additionally, by monitoring the height and overlap level of the flag section 30 in real-time during the welding process and reducing the defect rate through feedback control, battery life and stability are ensured.

[0145] Figure 2 This is a diagram illustrating an example of a welding process optimization apparatus for a secondary battery according to an embodiment of the present disclosure. For the welding process optimization apparatus for a secondary battery according to the present disclosure, detailed descriptions of portions that overlap with the welding process optimization method for secondary batteries described above will be omitted.

[0146] As shown in the figure, a welding process optimization apparatus for a secondary battery according to an embodiment of the present disclosure may include: a flag height setting unit 100 for setting the height of a flag 30; a modeling unit 200 for modeling a winding shape and a flag 30 shape using the set flag height; a visualization unit 300 for visually displaying the flag overlap based on the modeled shape; a data storage unit 400 for modeling and storing in a database the laser output value based on the visualized overlap data according to the overlap level of the flag 30; and a control unit 500 for measuring the flag height in real time during the welding process and controlling the laser output based on the information in the database.

[0147] According to one embodiment of this disclosure, changes that may occur in the welding process can be detected and responded to in real time, thereby improving the bonding quality between the secondary battery electrode and the current collector.

[0148] According to one embodiment of the present disclosure, the flag height setting unit 100 sets the height of the electrode flag 30 at the beginning stage of the welding process. The height of the flag 30 is a variable that directly affects the overlap level and laser output value in the welding process.

[0149] According to one embodiment of this disclosure, the modeling unit 200 models the winding shape and the shape of the flag section 30 based on the height setting value of the flag section 30, so as to simulate the overlap level of each flag section 30. By reflecting the width and height of the flag section 30, the modeling unit 200 calculates the winding shape using methods such as arithmetic sequences or Archimedes' spiral equations, thereby enabling the modeling unit 200 to predict the impact of the flag section 30 shape on the process.

[0150] According to one embodiment of the present disclosure, the visualization unit 300 visualizes the overlap of flags based on modeled shape information. The visualization unit 300 projects the overlap of each flag 30 onto an image plane and visualizes the overlap level through pixel values ​​or color brightness, thereby facilitating an intuitive understanding of the overlap state.

[0151] According to one embodiment of this disclosure, the data storage unit 400 databases the overlap level of the flag section 30 and the optimal laser output value matching it, based on visualized overlap data. The data storage unit 400 systematically manages this data and calls it in real time during the welding process to provide output that meets the welding conditions.

[0152] According to one embodiment of this disclosure, the control unit 500 dynamically adjusts the welding output by retrieving the optimal laser output value from a database based on the real-time height measurement value of the flag 30. The control unit 500, through the real-time feedback control system 600, quickly responds to changes in the height of the flag 30, maintaining welding quality.

[0153] As a specific embodiment of this disclosure, it may include a flag height setting unit 100, modeling software, a visualization program, a database system, and a feedback control module. After setting the flag height 30 at the initial stage of the process, the modeling software simulates and visualizes the winding shape and flag overlap at the corresponding height, and stores the optimal laser output value based on the overlap level in the database. When the flag height 30 is measured in real time during subsequent processes, the control unit 500 analyzes it, retrieves the optimal output value from the database, and adjusts the laser output.

[0154] Therefore, according to one embodiment of this disclosure, by responding instantly to changes in the height of the flag 30 based on real-time data, the bonding quality between the electrode and the current collector can be kept consistent, and real-time control can be achieved based on pre-modeled overlap and laser output values, thereby improving process speed and reducing defect rate.

[0155] Furthermore, the overlapping state can be easily grasped through visualized data, making process management and quality management more convenient. The welding process can be automatically adjusted through the feedback control system 600 of the control unit 500, thereby maintaining the stability and consistency of the process.

[0156] Therefore, according to one embodiment of this disclosure, a series of process optimizations are achieved, from setting the flag height to visualization, database management, and real-time control, thereby improving the welding quality of secondary batteries and increasing process efficiency.

[0157] According to one embodiment of this disclosure, the modeling unit 200 can set the width and height of the flag portion 30 in an arithmetic sequence, so that the size of the flag portion 30 gradually changes during winding. This can adjust the degree of overlap of the flag portions 30 to be constant, so as to maintain a uniform overlap state during winding and optimize the welding quality.

[0158] For example, the width and height of the flag section 30 are increased or decreased at constant intervals, so that each flag section 30 overlaps evenly during winding. This setting provides different overlap states for different positions of the wound flag sections 30 and achieves optimal welding conditions.

[0159] According to one embodiment of this disclosure, the modeling unit 200 calculates the winding angle of the flag section 30 using the Archimedes' spiral equation and applies a rotation matrix to simulate the winding shape of the flag section 30. This allows for precise control of the position and angle formed during the winding of the flag section 30, improving the accuracy of the welding process.

[0160] For example, the position and angle of each flag section 30 are pre-calculated according to the equation, and simulation is performed using a rotation matrix to ensure that the flag section 30 is positioned accurately during winding.

[0161] According to one embodiment of the present disclosure, the visualization unit 300 projects the flag overlap onto an image plane and displays it with different pixel values ​​according to the degree of overlap, so as to facilitate visual confirmation of the overlap level.

[0162] For example, areas with high overlap are displayed with bright pixel values, while areas with low overlap are displayed with dark pixel values, making it easy to visually confirm the overlap status.

[0163] This allows for a direct visual confirmation of the overlap status of the flag section 30, providing immediate feedback on the overlap level and enabling real-time quality management during the welding process.

[0164] According to one embodiment of this disclosure, the visualization section 300 can display the overlap level with different colors or brightness to distinguish the degree of overlap of the flag sections 30. This allows for clearer confirmation of the overlap status and improves welding quality.

[0165] For example, high overlap levels are displayed in dark or high-brightness colors, while low overlap levels are displayed in light or low-brightness colors, making it easy to grasp the changes in overlap at a glance.

[0166] According to one embodiment of the present disclosure, the data storage unit 400 may contain data that maps the overlap level of the flag height 30 to the optimal laser output value.

[0167] This data can be accessed in real time during the welding process to provide optimal laser output. For example, as the height of the flag 30 increases, the required laser output value can be automatically adjusted to optimize welding quality.

[0168] According to one embodiment of the present disclosure, the control unit 500 may include a feedback control system 600, which dynamically adjusts the laser output value based on the height of the flag 30 measured in real time during the welding process.

[0169] For example, when the height of the flag section 30 changes in real time during the process, the control unit 500 can detect the change and automatically adjust the output based on information from the database. This real-time feedback control instantly corrects for any changes that may occur in the welding process, thereby maintaining consistent welding quality.

[0170] According to one embodiment of this disclosure, the laser output value of the data storage unit 400 can be used for welding processes to achieve optimal bonding between the electrode and the current collector (CC).

[0171] According to this disclosure, the control unit 500 performs the welding process with reference to the laser output value stored in the data storage unit 400, and maintains the welding quality by applying a preset optimal laser output value based on the overlap state between the electrode and the current collector. For example, when the overlap state between the electrode and the current collector is optimal, the preset output value can be applied to optimize the joint quality.

[0172] Through these features, the present invention can precisely and efficiently optimize the welding process of secondary batteries and improve welding quality by using a flag height setting, visualization, database and real-time control system.

[0173] Figure 6 This is a diagram that visualizes the overlap of the flags according to an embodiment of the present disclosure.

[0174] As shown in the figure, the overlap level of the flag section is displayed with different pixel values ​​according to the degree of overlap, thereby visually distinguishing the overlap of each flag section area. For this overlap degree visualization, based on the flag height information set by the flag height setting unit 100, the modeling unit 200 models the coiled shape and the flag shape and displays them in image form, thereby confirming the degree of overlap.

[0175] Furthermore, the overlap level can be clearly distinguished through different colors or brightness levels. For example, from the center of the image outwards, areas with varying colors or brightness as the overlap increases indicate areas of greater flag overlap. This allows for a visual representation of flag overlap, enabling quantitative assessment of the overlap level and its database use in setting optimal laser output values.

[0176] Furthermore, this visualized overlap data can be stored in the data storage unit 400 as reference data in subsequent real-time welding processes. During real-time welding, the control unit 500 measures the flag height and adjusts the laser output based on the overlap information in the data storage unit 400, thereby achieving optimal welding of the flag.

[0177] Figure 7 This is a schematic diagram illustrating the process of modeling the optimal laser output value according to an embodiment of the present disclosure. It shows the process of pre-analyzing the optimal laser output value for the height of the flag 30 set by the flag height setting unit 100. This process aims to predict the changes in the height of the flag 30 and the corresponding overlap level, and to model the laser output value based on this to optimize the welding process. The flag 30 is formed by laser etching the uncoated portion 20 of the electrode at the edge of the electrode active material 10.

[0178] like Figure 7As shown in (a), each flag height 30 is defined based on the flag height data set by the flag height setting unit 100 according to an embodiment of the present disclosure. In this process, the flag height 30, as an important factor affecting the overlap level in the actual welding process, can be used as the main variable for the overlap level modeled by the modeling unit 200.

[0179] like Figure 7 As shown in (b), according to an embodiment of the present disclosure, the modeling unit 200 models the winding shape and the shape of the flag 30 based on a set flag height, thereby simulating the overlap level and visualizing the overlap level through color or shading, thus intuitively grasping the degree of overlap when the flag 30 is wound. This is the result achieved by the visualization unit 300 according to an embodiment of the present disclosure, showing the degree of overlap visualized through a simulation image based on the overlap level.

[0180] like Figure 7 As shown in (c), an overlap level model based on the height of the flag 30 is stored in a data storage unit 400 according to an embodiment of the present disclosure by a graph modeling how the overlap level changes as the height of the flag 30 increases. This model shows a pattern in which the overlap level gradually increases or decreases with respect to the height of the flag 30, thereby defining the relationship between the overlap level and the height of the flag 30.

[0181] like Figure 7 As shown in (d), a model is generated to determine the optimal laser output value when the overlap level reaches a specific level. Based on this model, the control unit 500 according to an embodiment of the present disclosure measures the height of the flag 30 in real time during the welding process, sets the optimal laser output value and performs welding by referring to the data of the overlap level model and the laser output model.

[0182] Thus, according to one embodiment of this disclosure, by pre-analysis and databaseization, the data storage unit 400 pre-stores the relationship between the overlap level of the flag height 30 and the optimal laser output value, and the control unit 500 can use this data to optimize the welding quality during real-time welding.

[0183] Figure 8 This is a schematic diagram of a process for optimizing a laser welding process based on real-time measurement of the height of the uncoated portion, according to an embodiment of the present disclosure.

[0184] As shown in the figure, according to one embodiment of this disclosure, a welding process optimization apparatus for secondary batteries is illustrated, which measures the height of the uncoated portion in real time, thereby setting the optimal laser output value and performing the welding process. This process is implemented by multiple components, including a control unit 500, a data storage unit 400, a flag height setting unit 100, and a modeling unit 200.

[0185] like Figure 8As shown in (a), the height measurement of the uncoated portion 20 is related to the flag height setting unit 100, and the height of the uncoated portion can be measured by a real-time laser etching process. According to an embodiment of this disclosure, the control unit 500 receives this data in real time and grasps the current height status of the flag 30.

[0186] like Figure 8 As shown in (b), the data storage unit 400 according to one embodiment of the present disclosure pre-constructs a database based on overlap level data of various flag heights 30. Thereby, the currently measured flag height 30 is compared with the overlap level data in the database, and the current overlap level is predicted. This overlap level database pre-generated by the modeling unit 200 according to one embodiment of the present disclosure can serve as data representing the correlation between flag height 30 and overlap level.

[0187] like Figure 8 As shown in (c), the data storage unit 400 according to one embodiment of the present disclosure contains data that maps the overlap level of the flag section 30 height to the optimal laser output value matching it. Thus, the optimal laser output value suitable for the current overlap level can be modeled and provided in real time. This process allows the control unit 500 to set an appropriate welding output based on the current overlap level of the flag section 30.

[0188] like Figure 8 As shown in (d), the final control unit 500 sets the laser output value based on information stored in the database and performs welding. The laser output value set here is determined with reference to the real-time measured height of the flag 30 and the optimal laser output value in the database, which can improve the quality of the welding process.

[0189] in this way, Figure 8 The process of determining the optimal laser output value based on the height of the flag 30 to optimize the welding process is shown, which can improve welding efficiency and quality.

[0190] Figure 9 This is a diagram of an electric vehicle illustrating a welding process optimization method and apparatus for a secondary battery according to an embodiment of the present disclosure.

[0191] Reference Figure 9 An electric vehicle 5000, which uses a welding process optimization method and apparatus for a secondary battery according to an embodiment of the present disclosure, can receive the power required for motor drive from a battery pack 50 with optimized welding process to drive itself.

[0192] Therefore, the performance and lifespan of the battery pack in the electric vehicle 5000 can be improved.

[0193] On the other hand, an electric vehicle 5000 according to an embodiment of the present disclosure may further include: a control system (e.g., an electronic control unit (ECU)) that communicates with a battery management system via a specified communication method (e.g., a control area network (CAN)); and at least one display for providing (e.g., displaying) various information of the electric vehicle 5000 (e.g., status information of the battery pack or cells included in the battery pack, operating information of the electric vehicle 5000, etc.).

[0194] Furthermore, the welding process optimization method and apparatus for secondary batteries according to an embodiment of this disclosure can be applied to various devices that receive power from battery modules or battery packs 50 whose welding quality has been improved through the above-described method and apparatus. For example, the welding process optimization method and apparatus for secondary batteries according to an embodiment of this disclosure can be applied to electric mobility devices (e.g., hybrid electric vehicles, electric bicycles, electric motorcycles, etc.) and energy storage systems (ESS).

[0195] Various embodiments of this disclosure can be implemented as software (e.g., a program) containing one or more instructions stored in a machine-readable storage medium (e.g., internal or external memory). For example, a processor of the machine (e.g., an electronic device) can invoke and execute at least one stored instruction from the storage medium. This enables the machine to operate to perform at least one function according to the invoked at least one instruction. The one or more instructions may include code generated by a compiler or code executable by an interpreter. The machine-readable storage medium may be provided as a non-transitory storage medium. Here, "non-transitory" means only that the storage medium is a tangible device and does not contain signals (e.g., electromagnetic waves); this term does not distinguish whether data is permanently or temporarily stored in the storage medium.

[0196] The methods according to various embodiments of this disclosure can be included in a computer program product. The computer program product can be traded as a commodity between buyers and sellers. The computer program product can be distributed in the form of a machine-readable storage medium (e.g., a compact disc read-only memory, CD-ROM) or distributed online (e.g., downloaded or uploaded) through an app store (e.g., the Play Store™) (or directly between two user devices (smartphones)). During online distribution, at least a portion of the computer program product can be temporarily stored or generated in a machine-readable storage medium such as the memory of a manufacturer's server, app store server, or relay server.

[0197] The above description is merely an example of applying the principles of this disclosure, and other configurations may be further included without departing from the scope of the invention. For example, at least some of the various embodiments of this disclosure described above may be combined.

Claims

1. A method for optimizing the welding process of a secondary battery, comprising the following steps: (a) Set the height of the electrode flag; (b) Model the coiled shape and the flag shape using the set flag height; (c) Visualize the overlap of the flags based on the modeled shape; (d) Based on the visualized overlap data, model and database the laser output values ​​according to the overlap level of the flags; and (e) The height of the flag is measured in real time during the welding process, and the optimal laser output is set using the information in the database.

2. The welding process optimization method for secondary batteries according to claim 1, wherein, In the winding shape modeling step of step (b), The width and height of the flag are set in an arithmetic sequence so that the size of the flag gradually changes during winding.

3. The welding process optimization method for secondary batteries according to claim 1, wherein, In the winding shape modeling step of step (b), The winding angle of the flag section is calculated using the Archimedes spiral equation, and a rotation matrix is ​​applied to each flag section to simulate the winding shape.

4. The welding process optimization method for secondary batteries according to claim 1, wherein, In the visualization step of step (c), The overlap of each flag is projected onto the image plane, so that it is displayed with different pixel values ​​according to the degree of overlap.

5. The welding process optimization method for secondary batteries according to claim 1, wherein, In the visualization step of step (c), Different colors or shades are used to indicate the level of overlap, in order to distinguish the degree of overlap in the flag sections.

6. The welding process optimization method for secondary batteries according to claim 1, wherein, The database in step (d) contains data that maps the overlap level of the flag height to the optimal laser output value.

7. The welding process optimization method for secondary batteries according to claim 1, wherein, In the welding process of step (e), the laser output value is dynamically adjusted according to the real-time measured height of the flag.

8. The welding process optimization method for secondary batteries according to claim 1, wherein, According to steps (d) and (e), a welding process is performed using a laser output value preset according to the overlap level of the flag to achieve optimal bonding between the electrode and the current collector.

9. A welding process optimization device for secondary batteries, comprising: Flag height setting unit, used to set the flag height; The modeling department uses the set flag height to model the coiled shape and the flag shape; The visualization section, based on the modeled shape, displays the overlap of the flag sections. The data storage unit, based on the visualized overlap data, models and stores the laser output values ​​according to the overlap level of the flags in a database. The control unit measures the height of the flag in real time during the welding process and controls the laser output based on the information in the database.

10. The welding process optimization device for secondary batteries according to claim 9, wherein, The modeling unit sets the width and height of the flag section in an arithmetic sequence, so that the size of the flag section gradually changes during winding.

11. The welding process optimization device for secondary batteries according to claim 9, wherein, The modeling unit uses the Archimedes spiral equation to calculate the winding angle of the flag and applies a rotation matrix to each flag to simulate the winding shape.

12. The welding process optimization device for secondary batteries according to claim 9, wherein, The visualization unit projects the overlap of each flag onto the image plane, so that it is displayed with different pixel values ​​according to the degree of overlap.

13. The welding process optimization device for secondary batteries according to claim 9, wherein, The visualization section displays the overlap level using different colors or brightness to distinguish the degree of overlap of the flag sections.

14. The welding process optimization device for secondary batteries according to claim 9, wherein, The data storage unit contains data that maps the overlap level based on the flag height to the optimal laser output value. The control unit includes a feedback control system, which dynamically adjusts the laser output value based on the flag height measured in real time during the welding process.

15. The welding process optimization device for secondary batteries according to claim 9, wherein, The welding process is performed using the laser output value of the data storage unit to achieve optimal bonding between the electrode and the current collector.

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