A processing method and system for cold welding nickel sheets on aluminum bars

Abstract

The present application relates to a kind of processing method and system of cold welding nickel piece to aluminum row, it relates to the technical field of new energy high-voltage electrical connection system, it includes: the production specification of the collection aluminum row and from production specification identification aluminum row to be welded area;Scan the surface of aluminum row to be welded area to collect the detection distribution information of oxide film;According to the assembly geometric parameter of aluminum row and nickel piece in production specification and electromagnetic pulse welding parameter, the impact speed and impact angle when electromagnetic welding are calculated;Based on detection distribution information, impact speed and impact angle are superimposed to analyze to identify the abnormal thickness grade of oxide film;Through abnormal thickness grade, porous sacrificial layer is generated in aluminum row to be welded area, and the cleaner of pre-set is immersed on porous sacrificial layer;When completing cleaner immersion, nickel piece is welded to aluminum row to be welded area with electromagnetic pulse welding parameter.The present application has the effect of improving the efficiency and yield of aluminum row surface treatment.

Description

Technical Field

[0001] This invention relates to the technical field of high-voltage electrical connection systems for new energy, and in particular to a method and system for cold-welding nickel sheets onto aluminum busbars. Background Technology

[0002] The new energy high-voltage electrical connection system is an operating system that ensures the safe and efficient transmission of high voltage and high current from the battery to various electrical components of the vehicle.

[0003] In new energy high-voltage electrical connection systems, aluminum busbars are increasingly widely used in battery packs and high-voltage DC charging systems. The electrical connection surfaces of extruded aluminum busbars typically undergo the following surface treatments: welding an electroplated copper terminal using laser welding or ultrasonic welding, or using polymer diffusion welding to bond a 0.1 to 0.2 mm thick nickel sheet. Because aluminum busbars readily oxidize in air, forming a high-melting-point oxide film, the surface needs to be physically polished or chemically de-oxidized before welding. Simultaneously, the high temperatures generated during polymer diffusion welding (typically around 600℃) can melt and damage the extruded insulation layer; therefore, a relatively long section of insulation near the weld (generally around 15 cm) needs to be removed. After polymer diffusion welding of the nickel sheet, an additional insulating layer such as heat-shrink tubing or insulating tape is added to complete the surface treatment of the extruded aluminum busbar.

[0004] In the process of surface treatment of extruded aluminum busbars, physical polishing or chemical removal of the oxide layer followed by welding of electroplated copper terminals or nickel sheets takes a long time and may damage the insulation layer of the aluminum busbar, reducing the efficiency and yield of aluminum busbar surface treatment. Summary of the Invention

[0005] To improve the efficiency and yield of aluminum busbar surface treatment, this invention provides a method and system for cold-welding nickel sheets onto aluminum busbars.

[0006] In a first aspect, the present invention provides a method for cold-welding nickel sheets onto aluminum busbars, employing the following technical solution: A method for cold-welding nickel sheets onto aluminum busbars, comprising: Collect the production specifications of the aluminum busbar and identify the areas of the aluminum busbar to be welded from the production specifications; The surface of the area to be welded on the aluminum busbar is scanned to collect information on the distribution of the oxide film. Based on the assembly geometry parameters of the aluminum busbar and nickel sheet and the electromagnetic pulse welding parameters in the production specifications, the impact velocity and impact angle during electromagnetic welding are calculated. The abnormal thickness level of the oxide film is identified by superimposing analysis based on the detection distribution information, impact velocity, and impact angle. A porous sacrificial layer is generated in the area to be welded on the aluminum busbar by an abnormal thickness level, and a preset cleaning agent is impregnated on the porous sacrificial layer. During the cleaning agent impregnation process, nickel sheets are welded to the aluminum busbar area to be welded using electromagnetic pulse welding parameters.

[0007] By adopting the above technical solution, a porous sacrificial layer is generated by producing aluminum busbars according to specifications and then impregnated with cleaning agent before electromagnetic pulse welding. This allows for the proactive construction of a gradient porous sacrificial layer and pre-installation of cleaning agent in high-risk areas of oxide film residue. During the welding process, the residual oxide film is removed along with the sacrificial layer. Physical polishing or chemical deoxidation of the oxide layer is no longer required before welding, and there is no need to worry about high temperature damage to the insulation layer and subsequent insulation restoration. This shortens the processing steps and improves the efficiency and yield of aluminum busbar surface treatment.

[0008] Optionally, methods for calculating impact velocity and impact angle include: Using electromagnetic pulse welding parameters and detection distribution information as boundary conditions, the detection variation parameters of aluminum busbars during electromagnetic pulse welding are simulated by assembling geometric parameters. The aluminum busbar to be welded area is divided according to the preset grid points to form an aluminum busbar to be welded area with grid points; Extract the detection velocity components of the aluminum busbar and nickel sheet at each grid point from the detected change parameters; The impact velocity and impact angle are calculated based on the detected velocity components and assembly geometry parameters.

[0009] By adopting the above technical solution, the electromagnetic pulse welding parameters and detection distribution information are used as boundary conditions to simulate the detection of changing parameters. Based on the extraction of velocity components from grid points, the impact velocity and impact angle are calculated, thereby providing accurate input data for subsequent superimposed analysis to identify abnormal thickness levels and improving the accuracy of abnormal zone identification.

[0010] Optionally, methods for identifying abnormal thickness levels include: Using the impact velocity field and impact angle field as inputs, the detection jet direction and jet coverage range of aluminum busbar and nickel sheet at the moment of welding are simulated; A jet intensity distribution map is generated based on the detected jet direction and jet coverage area; The thickness values ​​in the detection distribution information are compared with the preset reference thickness threshold to obtain abnormal thickness areas; The jet ineffective zone is obtained by comparing the intensity values ​​in the jet intensity distribution map with the preset reference intensity values. Combining the abnormal thickness region and the jet ineffective region, the overlapping area of ​​the two is taken as the abnormal partition region, and the thickness value of the abnormal partition region is taken as the abnormal thickness value. Match the abnormal thickness level based on the abnormal thickness value.

[0011] By adopting the above technical solution, a jet intensity distribution map is generated by simulating the jet direction and coverage. The abnormal thickness area is obtained by comparing with the thickness threshold, and the jet ineffective area is obtained by comparing with the intensity threshold. The overlapping area of ​​the two is taken as the abnormal partition area and matched with the thickness level. In this way, the high-risk area of ​​oxide film residue and its severity can be accurately identified, providing a quantitative basis for the generation of gradient porous sacrificial layer.

[0012] Optionally, methods for generating porous sacrificial layers include: The outline of the abnormal partition is obtained based on the abnormal partition region; The abnormal spacing between the contours of each abnormal partition is obtained; Calculate the difference in abnormal thickness levels between adjacent abnormal zones and use the difference as the abnormal deviation level; The porous generation parameters are obtained by using the abnormal thickness level and abnormal partition contour of adjacent abnormal partition regions. The range of influence is determined based on the abnormal spacing and the porous generation parameters; The porous generation parameters are updated based on the range of influence and the distribution and overlap of the abnormal partition contour, and the updated porous generation parameters are used as the porous sacrificial layer.

[0013] By adopting the above technical solution, the abnormal partition contours are extracted and the abnormal spacing and abnormal deviation levels are calculated. The influence range is obtained by combining the pore generation parameters. Then, the parameters are updated according to the contour overlap. Thus, the pore position and parameters can be adaptively adjusted according to the thickness level difference and spatial distance between adjacent abnormal areas, so that the pores are set in the middle of two thickness contours. While performing vertical micro-impact, it also removes the side oxide film, improving the coverage efficiency and removal effect of the cleaning agent.

[0014] Optionally, methods following the generation of the porous sacrificial layer include: Anodizing was performed using a porous sacrificial layer, and the detection characteristic waveforms of the aluminum busbar were collected during the anodizing process. The actual porosity is obtained based on the detected characteristic waveform; Extract the target porosity from the porous sacrificial layer; The porosity deviation rate is calculated by comparing the actual porosity with the target porosity. The porous sacrificial layer is updated based on the porosity deviation rate.

[0015] By adopting the above technical solution, the actual porosity is obtained by collecting and detecting characteristic waveforms during the anodizing process, and the porosity deviation rate is calculated by comparing it with the target porosity. The parameters of the porous sacrificial layer are dynamically updated according to the deviation rate, thereby realizing online monitoring and closed-loop control of the porosity in the porous sacrificial layer, ensuring that the actual generated porous structure meets the design requirements, and improving process consistency.

[0016] Optionally, methods of impregnating with a pre-defined cleaning agent include: Porosity was measured from the porous sacrificial layer. The volume of the impregnation solution is obtained by detecting the porosity and the cleaning agent. A immersion liquid distribution map is generated by combining the porous sacrificial layer and the immersion liquid volume. The cleaning agent is then sprayed onto the aluminum busbar area to be welded according to the immersion liquid distribution map.

[0017] By adopting the above technical solution, the volume of the impregnation liquid is calculated by detecting the porosity, and an impregnation liquid distribution map is generated by combining the porous sacrificial layer. The cleaning agent is then precisely sprayed onto the aluminum busbar to be welded according to the distribution map, thereby achieving the matching of cleaning agent dosage and porosity and the controllability of spatial distribution, reducing the situation of insufficient or excessive cleaning agent, and improving the cleaning effect and material utilization rate.

[0018] Optionally, methods for welding nickel sheets to the area to be welded on an aluminum busbar using electromagnetic pulse welding parameters include: The anomaly zone with the highest anomaly thickness level is selected as the risk zone. The target change rate and minimum current parameters are calculated based on the risk zone, impact velocity, and impact angle. When welding nickel sheets to the area to be welded on an aluminum busbar using electromagnetic pulse welding parameters, the rate of change in the position of the aluminum busbar is collected. The velocity deviation is calculated by comparing the velocity of position change with the velocity of target change. Update the minimum current parameter and the electromagnetic pulse welding parameter based on the speed deviation value.

[0019] By adopting the above technical solution, by selecting risk zones, calculating the target change rate and minimum current parameters, and collecting the aluminum busbar position change rate in real time during the welding process, comparing the calculated speed deviation value and dynamically updating the current parameters, a closed-loop control of electromagnetic pulse welding parameters is achieved, ensuring that high-risk areas receive sufficient collision energy to remove residual oxide film.

[0020] Optionally, methods for welding nickel sheets to the aluminum busbar area using electromagnetic pulse welding parameters include: Collect the contact resistance of the aluminum busbar area to be welded; A contact resistance distribution map is obtained based on the detected contact resistance and abnormal zones. The risk resistance region is obtained based on the risk zoning region; The contact resistance distribution map is spatially superimposed with the risk resistance region, and the reference contact resistance of the same grid point as the contact resistance distribution map is retrieved from the risk resistance region. The resistance deviation is calculated by comparing the tested contact resistance with the reference contact resistance. The range is increased by extracting weights from the risk zoning areas based on the resistance deviation values; The porous sacrificial layer is updated based on the weight increase range and resistance deviation value.

[0021] By adopting the above technical solution, a contact resistance distribution map is generated by detecting the contact resistance and superimposed on the risk resistance area. The resistance deviation value is calculated and the weight increase range is extracted. Based on this, the parameters of the porous sacrificial layer are updated, thus forming a closed-loop iterative system from detection, welding, feedback to optimization, which continuously improves the welding quality and yield of subsequent batches of aluminum busbars.

[0022] Optionally, methods for obtaining detection distribution information include: A scan path is constructed by combining the area to be welded on the aluminum busbar with a preset scan type; The surface of the aluminum busbar is scanned point by point along the scanning path, and the intensity of the detection spectral lines is collected. Based on the intensity of the detected spectral lines, the oxide film thickness value is matched using a preset benchmark calibration curve; The oxide film thickness values ​​at each scanning point are interpolated using a grid to generate detection distribution information.

[0023] By adopting the above technical solution, a scanning path is constructed, and the intensity of the detection spectral line is collected point by point along the path. The oxide film thickness value is matched by the calibration curve, and then the detection distribution information is generated by grid interpolation. This achieves high-resolution two-dimensional imaging of the oxide film thickness in the area to be welded on the aluminum busbar, providing accurate spatial distribution data for subsequent overlay analysis.

[0024] Secondly, this application provides a system for cold-welding nickel sheets onto aluminum busbars, employing the following technical solution: A system for cold-welding nickel sheets onto aluminum busbars, comprising: The acquisition module is used to acquire production specifications; A memory for storing a program for a method of cold-welding nickel sheets onto aluminum busbars; The processor is used to load and execute programs stored in memory.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. By producing a porous sacrificial layer and impregnating it with a cleaning agent according to the aluminum busbar production specifications, and then performing electromagnetic pulse welding, a gradient porous sacrificial layer can be actively constructed and a cleaning agent pre-placed in areas with high risk of oxide film residue. During the welding process, the residual oxide film is removed along with the sacrificial layer. There is no need to perform physical polishing or chemical deoxidation before welding, nor is there any need to worry about high temperature damage to the insulation layer and subsequent insulation restoration. This shortens the processing steps and improves the efficiency and yield of aluminum busbar surface treatment. 2. By simulating the jet direction and coverage, a jet intensity distribution map is generated. By comparing the thickness threshold, abnormal thickness areas are obtained, and by comparing the intensity threshold, jet ineffective areas are obtained. The overlapping areas of the two are taken as abnormal partition areas and matched with thickness levels, so as to accurately identify high-risk areas of oxide film residue and their severity, providing a quantitative basis for the generation of gradient porous sacrificial layers. 3. By extracting the abnormal partition contours and calculating the abnormal spacing and abnormal deviation levels, the influence range is obtained by combining the pore generation parameters. Then, the parameters are updated according to the contour overlap. Thus, the pore position and parameters can be adaptively adjusted according to the thickness level difference and spatial distance between adjacent abnormal areas, so that the pores are set in the middle of two thickness contours. While performing vertical micro-impact, it also removes the side oxide film, improving the coverage efficiency and removal effect of the cleaning agent. Attached Figure Description

[0026] Figure 1 This is a flowchart of a method for cold-welding nickel sheets onto aluminum busbars according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the structure of the aluminum busbar after cold welding of nickel sheets according to an embodiment of the present invention.

[0027] The parts referred to by the numbers in the above attached diagrams are as follows: 1. Aluminum busbar; 2. Nickel sheet; 3. Insulation layer. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0029] Reference Figure 1 and Figure 2 This application discloses a method for cold-welding nickel sheets onto aluminum busbars, comprising the following steps: S10: Collect the production specifications of aluminum busbar 1 and identify the area of ​​aluminum busbar to be welded from the production specifications.

[0030] Production specifications refer to the model, size, material (copper or aluminum) of aluminum busbar 1, the type of insulation layer 3 (PA11 / PA12 / PVC), extrusion process parameters, and the welding position requirements of nickel sheet 2. These specifications are obtained by retrieving them from the system after being pre-input by the operator.

[0031] The area to be welded on the aluminum busbar refers to the surface part of the aluminum busbar 1 where the insulation layer 3 needs to be removed and the nickel sheet 2 needs to be electrically connected and welded. The overlapping area between the aluminum busbar 1 and the nickel sheet 2 is selected from the production specifications as the area to be welded on the aluminum busbar.

[0032] In this embodiment, the insulating layer 3 completely covers the aluminum busbar 1. The figure only shows a partial covering to better observe the relationship between the aluminum busbar 1 and the insulating layer 3. While the insulating layer 3 completely covers the aluminum busbar 1, it does not cover the nickel sheets 2 that have been welded to both ends of the aluminum busbar 1.

[0033] S11: Scan the surface of the aluminum busbar area to be welded to collect information on the distribution of the oxide film.

[0034] The detection distribution information refers to the thickness and position distribution of the oxide film on the surface of the aluminum busbar to be welded. The area to be welded is scanned point by point using laser-induced breakdown spectroscopy (LIBS) or confocal microscopy to obtain the characteristic spectral intensity of aluminum and oxygen elements at each scanning point. Then, the oxide film thickness corresponding to the spectral intensity is obtained by converting the spectral intensity through a preset oxide film thickness-intensity calibration curve. The detection distribution information is formed by combining the position points of each scan with the corresponding oxide film thickness.

[0035] The oxide film thickness-intensity calibration curve is a curve set by technicians in advance through experiments: by preparing a set of standard alumina film samples with known thicknesses (e.g., 0 nm, 5 nm, 10 nm, 20 nm, 50 nm), the intensity ratio of aluminum and oxygen characteristic spectral lines (O / Al) of each sample is measured under the same LIBS detection conditions. Then, a nonlinear calibration curve is obtained by fitting the thickness as the vertical axis and the intensity ratio as the horizontal axis, which is used to back-calculate the measured spectral line intensity ratio into the oxide film thickness value.

[0036] S12: Based on the assembly geometry parameters of aluminum busbar 1 and nickel sheet 2 in the production specifications and the electromagnetic pulse welding parameters, calculate the impact speed and impact angle during electromagnetic welding.

[0037] Assembly geometry parameters refer to parameters such as the surface flatness of the aluminum busbar to be welded area, the thickness of nickel sheet 2 (0.1-0.2mm), the initial gap distance between aluminum busbar 1 and nickel sheet 2, and their relative spatial position relationship. The assembly geometry parameters of aluminum busbar 1 and nickel sheet 2 are retrieved from the production specifications.

[0038] Electromagnetic pulse welding parameters refer to the discharge voltage, peak current, pulse width, coil geometric parameters (number of turns, shape, inductance), and total resistance of the discharge circuit required for welding aluminum busbar 1 and nickel sheet 2. The electromagnetic pulse welding parameters required for welding aluminum busbar 1 and nickel sheet 2 are obtained from the production specifications.

[0039] Impact velocity refers to the normal velocity component at the moment of high-speed collision between the surface of aluminum busbar 1 (as a fly plate) and nickel sheet 2 during electromagnetic pulse welding. Impact angle refers to the angle between the direction of motion of aluminum busbar 1 and the normal to the welded surface at the moment of collision. Impact velocity and impact angle are obtained by analyzing the assembly geometry parameters of aluminum busbar 1 and nickel sheet 2 in the production specifications and the electromagnetic pulse welding parameters. The calculation and analysis methods for impact velocity and impact angle are described in S20 to S23 below.

[0040] In this embodiment, electromagnetic pulse welding is achieved using electromagnetic induction and thermal effects. During the welding process, an alternating magnetic field is generated by an AC power supply through a coil, and this magnetic field penetrates into the welding material. When contact resistance exists in the welding material, the alternating magnetic field causes current to flow through the material, thereby generating Joule heating and causing the material to heat up locally. When the local temperature exceeds the melting point of the welding material, the welding material melts and bonds together, achieving welding.

[0041] S13: Based on the detection distribution information, impact velocity, and impact angle, superimposed analysis is performed to identify the abnormal thickness level of the oxide film.

[0042] The abnormal thickness level refers to the classification based on the thickness value of the oxide film. It is obtained by superimposing and analyzing the detection distribution information, impact velocity, and impact angle. Specific analysis methods for the abnormal thickness level are detailed in S30 to S35.

[0043] S14: A porous sacrificial layer is generated in the area to be welded on the aluminum busbar by an abnormal thickness level, and a preset cleaning agent is impregnated on the porous sacrificial layer.

[0044] The cleaning agent is a low-melting-point metal (selected from gallium, indium or their eutectic alloys, with a melting point below 30°C) or a low-decomposition-temperature salt (selected from ammonium bicarbonate or ammonium oxalate, with a decomposition temperature below 100°C) specified by the technician. The cleaning agent is sprayed onto the porous sacrificial layer in the form of nanoparticle ink.

[0045] The porous sacrificial layer refers to an aluminum oxide film with a nanoscale porous structure generated on the surface of the area to be welded on the aluminum busbar through a local anodizing process. The porous sacrificial layer is obtained by analyzing the abnormal thickness level and is laid in the area to be welded on the aluminum busbar as a carrier for the cleaning agent. The oxide film is removed during electromagnetic pulse welding.

[0046] S15: After cleaning agent impregnation is completed, weld the nickel sheet 2 to the aluminum busbar area to be welded using electromagnetic pulse welding parameters.

[0047] After the porous sacrificial layer is laid and the cleaning agent is impregnated, the nickel sheet 2 is welded to the aluminum busbar area to be welded using electromagnetic pulse welding parameters.

[0048] Methods for calculating impact velocity and impact angle include: S20: Using electromagnetic pulse welding parameters and detection distribution information as boundary conditions, the detection variation parameters of aluminum busbar 1 during electromagnetic pulse welding are simulated by assembling geometric parameters.

[0049] The detected change parameters refer to the position, velocity, acceleration vector, and Lorentz force distribution of each mesh node on the surface of aluminum busbar 1 during electromagnetic pulse welding. The detected change parameters are obtained by constructing an electromagnetic-structure coupled finite element model (e.g., in COMSOL or LS-DYNA software), using the discharge voltage, peak current, and pulse width in the electromagnetic pulse welding parameters as excitation sources, and the initial gap and nickel sheet 2 thickness in the assembly geometry parameters as geometric constraints, and performing transient dynamic simulation calculations.

[0050] S21: Divide the aluminum busbar to be welded area according to the preset grid points to form an aluminum busbar to be welded area with grid points.

[0051] Mesh points are the basic spatial discrete units set by technicians for finite element simulation. They are quadrilateral or hexahedral in shape, with a maximum side length of no more than 0.5 mm, to ensure the calculation accuracy of the collision process.

[0052] By discretizing the geometric model of the aluminum busbar to be welded area into a numerical computation domain consisting of a finite number of grid points, each grid point has unique spatial coordinates to carry physical quantities (such as velocity and displacement) in the simulation process.

[0053] S22: Extract the detection velocity components of aluminum busbar 1 and nickel sheet 2 at each grid point from the detection change parameters.

[0054] The detection velocity component refers to the three decomposition values ​​of the instantaneous velocity vector at each grid node when the surface of aluminum strip 1 (flying plate) collides with nickel sheet 2 in the Cartesian coordinate system. The normal component (perpendicular to the welding plane) of the detection velocity component determines the impact kinetic energy, while the tangential component affects the jet direction.

[0055] Using the post-processing function of the simulation software, the velocity vector of each grid point at the collision moment (defined as the simulation time step when aluminum strip 1 and nickel sheet 2 first come into contact) is extracted from the detected changing parameters and output as the detection velocity component.

[0056] S23: Calculate the impact velocity and impact angle based on the detection velocity component and assembly geometry parameters.

[0057] For each grid node, the magnitude of the normal component of the detected velocity component is taken as the impact velocity of that node. The normal of the welding surface is retrieved from the electromagnetic pulse welding parameters, and the angle between the velocity vector and the normal of the welding surface is taken as the impact angle. Finally, spatial interpolation is performed on the results of all grid points to obtain the impact velocity and impact angle on the entire aluminum busbar to be welded area.

[0058] Methods for identifying abnormal thickness levels include: S30: Using the impact velocity field and impact angle field as inputs, simulate the detection jet direction and jet coverage of aluminum bar 1 and nickel sheet 2 at the moment of welding.

[0059] The direction of the jet is to be detected in the spatial orientation of the metal (aluminum and surface oxides) jet ejected from the interface gap by the high-speed impact of the flyplate on the substrate during the electromagnetic pulse welding collision process.

[0060] The jet coverage area refers to the area and specific location distribution of the aluminum busbar to be welded that can be swept by the metal jet. This range determines the effective area where the oxide film is physically removed. Using the impact velocity field and impact angle field as inputs, the detection jet direction of aluminum busbar 1 and nickel sheet 2 at the moment of welding is obtained through simulation using a fluid dynamics model (such as the Smooth Particle Hydrodynamics (SPH) method). The motion trajectory of the jet particles is tracked from the simulation of the fluid dynamics model, and the coordinate set of the particles impacting the surface of aluminum busbar 1 is extracted to form the coverage area.

[0061] S31: Generate a jet intensity distribution map based on the detected jet direction and jet coverage area.

[0062] A jet intensity distribution map is a two-dimensional cloud map that characterizes the intensity of metal jet scouring at each location on the area to be welded on the aluminum busbar. The intensity distribution map with the same resolution as the detection distribution information is generated by combining the detected jet direction and the jet coverage area obtained from the simulation.

[0063] S32: Compare the thickness values ​​in the detection distribution information with the preset baseline thickness threshold to obtain the abnormal thickness region.

[0064] The baseline thickness threshold is a thickness threshold set by technicians to determine whether a porous sacrificial layer needs to be laid. For example, taking an aluminum busbar sample 1 from the same batch, measuring its original oxide film thickness, then welding a nickel sheet 2 under standard EMPT process and measuring the contact resistance, the oxide film thickness corresponding to a contact resistance exceeding 12μΩ is the baseline thickness threshold. If no calibration data is available, 15nm is used by default.

[0065] An abnormal thickness region refers to a region in the detection distribution information where the thickness value exceeds the reference thickness threshold. By retrieving the thickness value of each grid point from the detection distribution information and comparing each thickness value with the reference thickness threshold, the discrete or connected regions formed by connecting grid points whose thickness values ​​exceed the reference thickness threshold are considered as abnormal thickness regions.

[0066] S33: Compare the intensity values ​​in the jet intensity distribution map with the preset reference intensity values ​​to obtain the jet ineffective zone.

[0067] The reference strength value is the minimum jet strength set by the technician required to completely remove the oxide film of the reference thickness.

[0068] The jet ineffective zone refers to the region in the jet intensity distribution map where the intensity value is less than the reference intensity value. By retrieving the intensity values ​​of each grid point from the jet intensity distribution map and comparing each intensity value with the reference intensity value, the discrete or connected regions formed by connecting grid points with intensity values ​​less than the reference intensity value are regarded as the jet ineffective zone.

[0069] S34: Combining the abnormal thickness region and the jet ineffective region, the overlapping area of ​​the two is taken as the abnormal partition region, and the thickness value of the abnormal partition region is taken as the abnormal thickness value.

[0070] An abnormal partition region refers to the overlapping area between the abnormal thickness region and the jet ineffective region. The abnormal partition region is defined as the spatially overlapping area between the abnormal thickness region and the jet ineffective region.

[0071] Abnormal thickness value refers to the thickness value of an abnormal partition region, which is used as the abnormal thickness value.

[0072] S35: Match the abnormal thickness level according to the abnormal thickness value.

[0073] The abnormal thickness level is determined by matching the abnormal thickness value from a preset thickness mapping table. For example, Level 1 (abnormal thickness < 15nm), Level 2 (15nm ≤ abnormal thickness < 30nm), and Level 3 (abnormal thickness ≥ 30nm). If multiple levels exist within the same abnormal zone, the highest level among all grid points in the zone is taken as the level of that zone.

[0074] The thickness mapping table stores the abnormal thickness levels corresponding to different abnormal thickness values. The parameters in the thickness mapping table are set in advance by those skilled in the art based on actual conditions.

[0075] Method for establishing the thickness mapping table: Using aluminum busbar samples from the same batch, the oxide film thickness was measured (using an ellipsometry). EMPT welding was performed according to the thickness range (<15nm, 15~30nm, >30nm), and the contact resistance was tested. The abnormal thickness level was determined based on whether the contact resistance was below 5μΩ. For example: thickness <15nm was defined as Level 1 (no treatment required), 15~30nm as Level 2 (requires a low-porosity sacrificial layer), and >30nm as Level 3 (requires a high-porosity sacrificial layer).

[0076] Methods for generating porous sacrificial layers include: S40: Obtain the outline of the abnormal partition based on the abnormal partition region.

[0077] The abnormal partition contour refers to the boundary line of the abnormal partition area on the plane of the aluminum busbar to be welded. The boundary line corresponding to the abnormal partition area is used as the abnormal partition contour.

[0078] S41: Obtain the abnormal spacing between the contours of each abnormal partition.

[0079] Anomaly spacing refers to the shortest straight-line distance between two different anomaly partition contours. It is calculated by sequentially determining the minimum distance between adjacent contours (sorted by spatial location) as the anomaly spacing.

[0080] S42: Calculate the difference in abnormal thickness levels between adjacent abnormal zones and use the difference as the abnormal deviation level.

[0081] The abnormal deviation level refers to the absolute value of the difference between the abnormal thickness levels of two adjacent abnormal partition areas. The abnormal deviation level is obtained by retrieving the abnormal thickness levels between adjacent abnormal partition areas and then calculating the difference between the two abnormal thickness levels.

[0082] S43: The porous generation parameters are obtained by using the abnormal thickness level and abnormal partition contour of adjacent abnormal partition regions.

[0083] Pore ​​generation parameters refer to the set of parameters used to control the local anodizing process, including: anodizing voltage (10-60V), current density (0.5-5A / dm³), etc. 2 The parameters include: processing time (10-180 seconds), electrolyte type (phosphoric acid / oxalic acid / sulfuric acid), target porosity, and target pore size.

[0084] The target porosity and target pore size are matched from the thickness mapping table by the abnormal thickness level. Then, the geometry of the abnormal partition contour (such as the contour area and the minimum bounding rectangle size) is used as input to locally modify the porosity and target pore size: the larger the contour area or the narrower the contour, the porosity is appropriately increased in some areas within the contour (for example, by 5% to 10%) to enhance the uniformity of detergent coverage, thereby forming the final porous generation parameters.

[0085] S44: The range of influence is obtained based on the abnormal spacing and the porous generation parameters.

[0086] The influence range refers to the radius of the surrounding area that a single pore or a group of pores can effectively clean. This radius is related to the dosage of the cleaning agent, the pore diameter, and the abnormal spacing. The influence range is determined by matching the abnormal spacing with the pore generation parameters from a preset cleaning mapping table.

[0087] The cleaning mapping table stores the influence ranges corresponding to different abnormal spacings and the dosage and pore diameter of the cleaning agent in the pore formation parameters. The parameters in the cleaning mapping table are set in advance by those skilled in the art based on actual conditions through experiments.

[0088] The cleaning mapping table is prepared by local anodizing of a porous layer with different pore sizes (20nm, 50nm, 100nm) and porosities (20%, 40%, 60%) on a standard aluminum busbar 1. After spraying a quantitative cleaning agent, EMPT welding is performed. The jet particle splash radius is measured by high-speed camera to obtain the relationship between (pore size, porosity, cleaning dosage) and the influence range and store the data.

[0089] S45: Update the pore generation parameters according to the range distribution and overlap of the influence range and the abnormal partition contour, and use the updated pore generation parameters as the pore sacrificial layer.

[0090] When the influence ranges of adjacent abnormal partition contours overlap, the porous generation parameters corresponding to the overlapping areas are merged or weighted averaged. For example, the larger of the porosity target values ​​of the two regions is taken, and the geometric center of the pores is adjusted to the geometric midline of the two contours, so that a pore group can simultaneously serve the oxide film removal on both sides. Finally, through spatial overlay analysis, the optimized porous generation parameters are recalculated for each abnormal partition region according to the above logic of influence range and abnormal partition contour as a porous sacrificial layer.

[0091] Methods for generating porous sacrificial layers include: S50: Anodizing is performed using a porous sacrificial layer, and the detection characteristic waveform of aluminum busbar 1 is acquired during the anodizing process.

[0092] The detection characteristic waveform refers to the periodic oscillation signal on the surface of aluminum busbar 1 during the anodizing process. The voltage across the electrolytic cell is recorded by a data acquisition card at a sampling rate of not less than 100Hz, or the voltage-time curve or current-time curve formed by the current in the electrolytic circuit is used as the detection characteristic waveform.

[0093] S51: Obtain the actual porosity based on the detected characteristic waveform.

[0094] Actual porosity refers to the volume percentage or area percentage of pores in the currently generated oxide film. The oscillation frequency is obtained by analyzing the oscillation period or the main frequency of the fast Fourier transform (FFT) in the characteristic waveform. According to the empirical formula: porosity = oscillation frequency * f + b, where f and b are calibration constants obtained by those skilled in the art through prior experiments.

[0095] The calibration constant was obtained by preparing five groups of porous alumina samples under the same electrolyte (oxalic acid, concentration 0.3 mol / L) and temperature (20±1℃). The actual porosity (area percentage) of each sample cross-section was measured by scanning electron microscopy (SEM), and the current oscillation frequency (FFT dominant frequency) during the anodizing process was recorded. The five sets of data (frequency, porosity) were linearly fitted to obtain the calibration constant. For different electrolyte formulations, recalibration is required.

[0096] S52: Extract the target porosity from the porous sacrificial layer.

[0097] The target porosity refers to the standard porosity in the porous sacrificial layer, which is obtained by extracting the target porosity from the porous sacrificial layer.

[0098] S53: Compare the actual porosity with the target porosity to calculate the porosity deviation rate.

[0099] Pore ​​deviation rate refers to the deviation between the actual porosity and the target porosity. It is calculated by taking the difference between the actual porosity and the target porosity as the porosity deviation rate.

[0100] S54: Update the porous sacrificial layer based on the porosity deviation rate.

[0101] The required increase or decrease in voltage and processing time for generating a porous sacrificial layer is matched from the cleaning map table by the porosity deviation rate, and then summed with the voltage and processing time corresponding to the original porous sacrificial layer to obtain the new voltage and processing time as parameters in the new porous sacrificial layer.

[0102] The cleaning mapping table stores the voltage and processing time corresponding to different porosity deviation rates. When the porosity deviation rate is negative, the voltage needs to be increased or the processing time needs to be extended. When the porosity deviation rate is positive, the voltage needs to be decreased or the processing time needs to be shortened.

[0103] Methods of impregnating with a pre-set cleaning agent include: S60: Extract the porosity from the porous sacrificial layer.

[0104] The detected porosity refers to the porosity in the porous sacrificial layer after the S54 update, which is obtained by retrieving the detected porosity from the porous sacrificial layer.

[0105] S61: The volume of the impregnation solution is obtained by detecting the porosity and cleaning agent.

[0106] The impregnation volume refers to the volume of cleaning agent required to fill the pores in the porous sacrificial layer. The impregnation volume is calculated by detecting the porosity and the cleaning agent.

[0107] The volume of the impregnation solution = the coverage volume of the porous sacrificial layer (area multiplied by average thickness) × the detected porosity × η, where η is the interference coefficient corresponding to the cleaning agent, ranging from 1.0 to 1.3, and is determined experimentally based on the viscosity of the cleaning agent and the surface tension of the porous sacrificial layer (e.g., for low-viscosity liquid gallium, η is 1.05; for salt solutions, η is 1.2). If no calibration data is available, 1.1 is used by default.

[0108] S62: Combine the porous sacrificial layer with the volume of the impregnation liquid to generate an impregnation liquid distribution map, and spray the cleaning agent onto the aluminum busbar to be welded area according to the impregnation liquid distribution map.

[0109] The impregnation liquid distribution map is a two-dimensional mapping map that marks the required volume of cleaning agent to be sprayed at each position on the aluminum busbar to be welded area. By spatially distributing the volume of impregnation liquid according to the porosity of each region of the porous sacrificial layer, the target spraying amount of each grid point is obtained, forming a dot matrix spraying command. The two-dimensional distribution mapping map of the target spraying amount and the corresponding dot matrix spraying command is used as the impregnation liquid distribution map. Finally, the cleaning agent is sprayed onto the aluminum busbar to be welded area according to the impregnation liquid distribution map.

[0110] Methods for welding nickel sheet 2 to the aluminum busbar area using electromagnetic pulse welding parameters include: S70: Select the abnormal partition area with the largest abnormal thickness level as the risk partition area.

[0111] Risk zoning areas refer to one or more areas with the highest abnormality thickness level among the abnormal zoning areas (if multiple areas have the same level, all of them are included). The abnormal zoning area with the highest abnormality thickness level is selected as the risk zoning area from among the various abnormal zoning areas.

[0112] S71: Calculate the target change rate and minimum current parameters based on the risk zone, impact velocity, and impact angle.

[0113] The target change rate refers to the minimum collision velocity required to completely remove the oxide film within the risk zone. It is calculated by analyzing the impact velocities within the risk zone, taking the minimum impact velocity within the risk zone, and then multiplying it by a safety factor (usually 1.1~1.3) as the target change rate.

[0114] The minimum current parameter refers to the minimum discharge voltage and minimum current slope required for the electromagnetic pulse welding equipment to achieve the target change rate. The minimum current parameter is matched from the cleaning map table by the impact velocity and impact angle in the risk zone.

[0115] The cleaning map stores the minimum current parameters corresponding to different impact velocities and impact angles. The cleaning map was obtained through experimental calibration: a standard aluminum busbar sample was selected, and under the conditions of set impact velocity and impact angle, the discharge voltage and current slope were gradually increased. When the actual collision velocity first reached the target change velocity, the discharge voltage and current slope at this time were recorded as the minimum current parameters. For combinations not in the table, linear interpolation was used for calculation.

[0116] S72: When welding the nickel sheet 2 to the aluminum busbar area to be welded using electromagnetic pulse welding parameters, the position change rate of the aluminum busbar 1 is collected.

[0117] The position change rate refers to the speed at which the position of the aluminum busbar 1 changes during the welding discharge process. When the nickel sheet 2 is welded to the area to be welded on the aluminum busbar using electromagnetic pulse welding parameters, the position of the surface of the aluminum busbar 1 is measured in real time by a high-speed fiber optic interferometer, and the instantaneous velocity value obtained by combining the first derivative with time is used as the position change rate.

[0118] S73: Calculate the velocity deviation by comparing the velocity of position change with the velocity of target change.

[0119] The velocity deviation value refers to the deviation between the velocity of position change and the velocity of target change. It is calculated as the difference between the velocity of position change and the velocity of target change.

[0120] S74: Update the minimum current parameter and the electromagnetic pulse welding parameter based on the speed deviation value.

[0121] When a velocity deviation exists, the adjustable inductor or solid-state switch array in the discharge circuit is adjusted using a closed-loop control algorithm to change the current slope or discharge voltage, causing the position change rate to converge towards the target change rate. Specifically, the adjustment strategy is as follows: if the velocity deviation is negative, the series inductor is reduced to increase the current slope or the discharge voltage. If the velocity deviation is positive, the series inductor is increased to decrease the current slope or the discharge voltage. The adjusted electromagnetic pulse welding parameters are immediately applied to the remaining phase of the current welding pulse (if multi-pulse welding is used) or recorded for welding the next aluminum busbar 1.

[0122] In this embodiment, the high-speed fiber optic interferometer has a sampling frequency of up to 100MHz (i.e., one data point every 10 nanoseconds), which can completely capture the speed changes of the flyboard within 20-50 microseconds. The adjustable inductor is controlled by a solid-state switch array (such as SiC MOSFET), with a response time of less than 100 nanoseconds. The closed-loop control algorithm is implemented based on FPGA hardware, and the total delay from speed sampling to inductor adjustment is less than 200 nanoseconds.

[0123] Furthermore, when updating electromagnetic pulse welding parameters, the current slope should be adjusted first (by changing the inductance). If convergence is still not achieved even after the inductance has been adjusted to its limit, then the discharge voltage should be adjusted. The adjustment amount of the current slope or discharge voltage is proportionally controlled: adjustment amount = K × speed deviation value, where K is the proportional coefficient preset by the equipment.

[0124] The method for welding nickel sheet 2 to the area to be welded on aluminum busbar using electromagnetic pulse welding parameters includes: S80: Collects the contact resistance of the aluminum busbar area to be welded.

[0125] The contact resistance test refers to the resistance value of the nickel sheet 2 surface in the area to be welded on the aluminum busbar. The resistance value is measured on the surface of the nickel sheet 2 in the area to be welded on the aluminum busbar using the four-probe method or a micro-ohmmeter, and is used to characterize the conductivity of the welding interface.

[0126] S81: Obtain the contact resistance distribution map based on the detected contact resistance and abnormal zone areas.

[0127] A contact resistance distribution map is a two-dimensional cloud map generated in an abnormal partition area that relates to the contact resistance value. The two-dimensional cloud map generated by combining the contact resistance values ​​of each grid point in the abnormal partition area is used as the contact resistance distribution map.

[0128] S82: Obtain the risk resistance region based on the risk partitioning region.

[0129] The risk resistance region refers to the corresponding area of ​​the risk zone in the contact resistance distribution map. By superimposing the outline of the risk zone onto the contact resistance distribution map, all grid points within the outline are extracted as the risk resistance region.

[0130] S83: Spatially overlay the contact resistance distribution map with the risk resistance region, and retrieve the reference contact resistance from the risk resistance region at the same grid point as the contact resistance distribution map.

[0131] The reference contact resistance refers to the surface resistance after the oxide film has been removed. It is obtained by spatially superimposing the contact resistance distribution map with the risk resistance area, and then retrieving the reference contact resistance from the risk resistance area at the same grid point as the contact resistance distribution map.

[0132] S84: Compare the tested contact resistance with the reference contact resistance to calculate the resistance deviation value.

[0133] The resistance deviation value refers to the relative deviation between the measured contact resistance and the reference contact resistance at each grid point within the risk resistance area. The resistance deviation value is calculated by comparing the measured contact resistance with the reference contact resistance at the same grid point.

[0134] S85: Extract weights from the risk zone based on the resistance deviation value to increase the range.

[0135] The weight increase range refers to the range of resistance deviation values ​​in the risk partition area. The range of resistance deviation values ​​extracted from the risk partition area is used as the weight increase range.

[0136] S86: Update the porous sacrificial layer based on the weight increase range and resistance deviation value.

[0137] When extracting the weight increase range, the weight coefficient value is matched from the cleaning map table using the resistance deviation value. This weight coefficient value is then added to each grid point within the weight increase range to form a new weight increase range. Based on this weight coefficient value, the porosity and pore size in the original porous sacrificial layer are increased to obtain a new porous sacrificial layer.

[0138] Methods for obtaining detection distribution information include: S90: Construct a scan path by combining the area to be welded on the aluminum busbar with a preset scan type.

[0139] The scanning type is a point-by-point scanning method set by the technician, including raster scanning (reciprocating linear), spiral scanning, or adaptive scanning (automatically densifying the scanning points in areas where the oxide film thickness changes drastically).

[0140] The scan path refers to the scan sequence trajectory formed according to the scan type. Each scan point is marked on the aluminum busbar to be welded according to the scan type, and the scan points are connected in order according to the scan type to form the scan path.

[0141] S91: Scan the surface of aluminum busbar 1 point by point along the scanning path and collect the intensity of the detection spectral lines.

[0142] The intensity of the detected spectral line refers to the spectral detection signal obtained after scanning the surface of aluminum busbar 1.

[0143] In-situ spectroscopic detection methods are used to scan the area to be welded point by point, acquiring the physical or chemical response signal at each scan point. These in-situ spectroscopic detection methods include: laser-induced breakdown spectroscopy (LIBS), elliptic polarization spectroscopy, reflectance spectroscopy, or electrochemical impedance spectroscopy (EIS). LIBS calculates the thickness by measuring the intensity of characteristic spectral lines of aluminum and oxygen and combining this with calibration curves. Elliptic polarization spectroscopy calculates the thickness by measuring the polarization state change of reflected light and inverting it using an optical model. Reflectance spectroscopy calculates the thickness by analyzing the interference spectra of reflected light from the upper and lower surfaces of the thin film. EIS measures the impedance spectrum of the electrodes during the anodizing process.

[0144] S92: Based on the intensity of the detected spectral lines, the oxide film thickness value is matched with a preset benchmark calibration curve.

[0145] The reference calibration curve is the curve of the thickness of the oxide film appearing on the surface of aluminum busbar 1, which is converted from the spectral detection signal set by the technician. Different in-situ spectroscopic detection methods in S91 have different reference calibration curves.

[0146] Establishment of the benchmark calibration curve (using LIBS as an example): Five sets of standard aluminum sheets with known oxide film thicknesses (0, 5, 10, 20, 50 nm) were prepared. The O / Al spectral line intensity ratio was measured. The curve equation was obtained by logarithmic fitting with thickness as the dependent variable and intensity ratio as the independent variable.

[0147] The oxide film thickness value refers to the thickness of the oxide film appearing on the surface of aluminum busbar 1. The corresponding thickness value is obtained by detecting the spectral intensity and substituting it into the reference calibration curve.

[0148] S93: The oxide film thickness values ​​at each scanning point are interpolated using a grid to generate detection distribution information.

[0149] The coordinates of all scanning points on the scanning path and their corresponding oxide film thickness values ​​are used to generate a two-dimensional distribution map covering the entire aluminum busbar to be welded area as detection distribution information through a gridded interpolation algorithm (such as inverse distance weighting, Kriging, or radial basis function).

[0150] Based on the same inventive concept, embodiments of the present invention provide a system for cold-welding nickel sheets onto aluminum busbars, comprising: The acquisition module is used to acquire production specifications; A memory for storing a program for a method of cold-welding nickel sheets onto aluminum busbars; The processor is used to load and execute programs stored in memory.

[0151] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0152] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for cold-welding nickel sheets onto aluminum busbars, characterized in that, include: Collect the production specifications of aluminum busbar (1) and identify the area of ​​aluminum busbar to be welded from the production specifications; The surface of the area to be welded on the aluminum busbar is scanned to collect information on the distribution of the oxide film. Based on the assembly geometry parameters of aluminum busbar (1) and nickel sheet (2) in the production specifications and the electromagnetic pulse welding parameters, the impact speed and impact angle during electromagnetic welding are calculated. The abnormal thickness level of the oxide film is identified by superimposing analysis based on the detection distribution information, impact velocity, and impact angle. A porous sacrificial layer is generated in the area to be welded on the aluminum busbar by an abnormal thickness level, and a preset cleaning agent is impregnated on the porous sacrificial layer. When the cleaning agent impregnation is completed, the nickel sheet (2) is welded to the aluminum busbar area to be welded using electromagnetic pulse welding parameters.

2. The method for cold-welding nickel sheets onto aluminum busbars according to claim 1, characterized in that, Methods for calculating impact velocity and impact angle include: Using electromagnetic pulse welding parameters and detection distribution information as boundary conditions, the detection change parameters of aluminum busbar (1) during electromagnetic pulse welding are simulated by assembling geometric parameters; The aluminum busbar to be welded area is divided according to the preset grid points to form an aluminum busbar to be welded area with grid points; Extract the detection velocity components of aluminum busbar (1) and nickel sheet (2) at each grid point from the detection change parameters; The impact velocity and impact angle are calculated based on the detected velocity components and assembly geometry parameters.

3. The method for cold-welding nickel sheets onto aluminum busbars according to claim 2, characterized in that, Methods for identifying abnormal thickness levels include: Using the impact velocity field and impact angle field as inputs, the detection jet direction and jet coverage of the aluminum bar (1) and nickel sheet (2) at the moment of welding are simulated; A jet intensity distribution map is generated based on the detected jet direction and jet coverage area; The thickness values ​​in the detection distribution information are compared with the preset reference thickness threshold to obtain abnormal thickness areas; The jet ineffective zone is obtained by comparing the intensity values ​​in the jet intensity distribution map with the preset reference intensity values. Combining the abnormal thickness region and the jet ineffective region, the overlapping area of ​​the two is taken as the abnormal partition region, and the thickness value of the abnormal partition region is taken as the abnormal thickness value. Match the abnormal thickness level based on the abnormal thickness value.

4. The method for cold-welding nickel sheets onto aluminum busbars according to claim 3, characterized in that, Methods for generating porous sacrificial layers include: The outline of the abnormal partition is obtained based on the abnormal partition region; The abnormal spacing between the contours of each abnormal partition is obtained; Calculate the difference in abnormal thickness levels between adjacent abnormal zones and use the difference as the abnormal deviation level; The porous generation parameters are obtained by using the abnormal thickness level and abnormal partition contour of adjacent abnormal partition regions. The range of influence is determined based on the abnormal spacing and the porous generation parameters; The porous generation parameters are updated based on the range of influence and the distribution and overlap of the abnormal partition contour, and the updated porous generation parameters are used as the porous sacrificial layer.

5. A method for cold-welding nickel sheets onto aluminum busbars according to claim 4, characterized in that, Methods for generating porous sacrificial layers include: Anodizing was performed using a porous sacrificial layer, and the detection characteristic waveforms of the aluminum busbar (1) were collected during the anodizing process; The actual porosity is obtained based on the detected characteristic waveform; Extract the target porosity from the porous sacrificial layer; The porosity deviation rate is calculated by comparing the actual porosity with the target porosity. The porous sacrificial layer is updated based on the porosity deviation rate.

6. The method for cold-welding nickel sheets onto aluminum busbars according to claim 4, characterized in that, Methods of impregnating with a pre-set cleaning agent include: Porosity was measured from the porous sacrificial layer. The volume of the impregnation solution is obtained by detecting the porosity and the cleaning agent. A immersion liquid distribution map is generated by combining the porous sacrificial layer and the immersion liquid volume. The cleaning agent is then sprayed onto the aluminum busbar area to be welded according to the immersion liquid distribution map.

7. A method for cold-welding nickel sheets onto aluminum busbars according to claim 6, characterized in that, Methods for welding nickel sheets (2) to the aluminum busbar area using electromagnetic pulse welding parameters include: The anomaly zone with the highest anomaly thickness level is selected as the risk zone. The target change rate and minimum current parameters are calculated based on the risk zone, impact velocity, and impact angle. When the nickel sheet (2) is welded to the area to be welded on the aluminum busbar using electromagnetic pulse welding parameters, the position change rate of the aluminum busbar (1) is collected. The velocity deviation is calculated by comparing the velocity of position change with the velocity of target change. Update the minimum current parameter and the electromagnetic pulse welding parameter based on the speed deviation value.

8. A method for cold-welding nickel sheets onto aluminum busbars according to claim 7, characterized in that, The method of welding nickel sheet (2) to the area to be welded on aluminum busbar using electromagnetic pulse welding parameters includes: Collect the contact resistance of the aluminum busbar area to be welded; A contact resistance distribution map is obtained based on the detected contact resistance and abnormal zones. The risk resistance region is obtained based on the risk zoning region; The contact resistance distribution map is spatially superimposed with the risk resistance region, and the reference contact resistance of the same grid point as the contact resistance distribution map is retrieved from the risk resistance region. The resistance deviation is calculated by comparing the tested contact resistance with the reference contact resistance. The range is increased by extracting weights from the risk zoning areas based on the resistance deviation values; The porous sacrificial layer is updated based on the weight increase range and resistance deviation value.

9. A method for cold-welding nickel sheets onto aluminum busbars according to claim 1, characterized in that, Methods for obtaining detection distribution information include: A scan path is constructed by combining the area to be welded on the aluminum busbar with a preset scan type; The surface of the aluminum busbar (1) is scanned point by point along the scanning path, and the intensity of the detection spectral lines is collected. Based on the intensity of the detected spectral lines, the oxide film thickness value is matched using a preset benchmark calibration curve; The oxide film thickness values ​​at each scanning point are interpolated using a grid to generate detection distribution information.

10. A system for cold-welding nickel sheets onto aluminum busbars, characterized in that, include: The acquisition module is used to acquire production specifications; A memory for storing a program for implementing a method for cold-welding nickel sheets onto an aluminum busbar as described in any one of claims 1 to 9; The processor is used to load and execute programs stored in memory.

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