Equipment and methods for testing the condition of ultrasonic welding machines.

Abstract

The invention relates to a device for testing the state of an ultrasonic welding machine, comprising: a 3D scanner for scanning the weld mold in the welding rod of the ultrasonic welding machine and the notch pattern located at one end of this weld mold to calculate data on the height of each notch in the notch pattern; and a controller for determining the state of the ultrasonic welding machine based on the notch height data in the notch pattern output from the 3D scanner.

Description

Device and method for inspecting the condition of an ultrasonic welder

[0001] This application claims the benefit of Korean Patent Application No. 10-2023-0186577 filed with the Korean Intellectual Property Office on December 20, 2023, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a device and method for inspecting the condition of an ultrasonic welder, and more specifically, to a device and method for inspecting the condition of an ultrasonic welder using a 3D scanner.

[0003] Secondary batteries are batteries that can be reused by charging even after discharge, and can be used as an energy source for small devices such as mobile phones, tablet PCs, and vacuum cleaners, and are also used as medium- to large-scale energy sources such as personal mobility, automobiles, and ESS (Energy Storage Systems) for smart grids.

[0004] Cylindrical, prismatic, and pouch-shaped batteries are known as unit secondary battery cell types. Cylindrical batteries have recently been expanding in size due to their application in electric vehicles, and cell-to-pack structures are becoming increasingly common. Cylindrical batteries can be manufactured by interposing a separator (an insulator) between the positive and negative electrodes, winding the separator to form a jelly-roll-shaped electrode assembly, and then inserting this assembly into a battery housing (battery can).

[0005] At this point, welding is required to electrically connect the battery can and the current collector plate. Laser welding, spot welding, or ultrasonic welding can be used as welding methods. Ultrasonic welding, used in the secondary battery manufacturing process, utilizes ultrasonic welding rods. If the electrodes become worn, the weld quality will be affected. Therefore, it's necessary to check the wear of the ultrasonic welding rods and replace them accordingly.

[0006] Typically, to check the wear of a welding electrode, the electrode horn is removed and measured offline using an offline measuring device. Therefore, real-time monitoring of electrode wear is difficult, and related manufacturing equipment is often forced to shut down for relatively long periods. This problem increases the likelihood of defective cells being produced due to the use of defective electrodes, and can also reduce the operational efficiency of manufacturing equipment.

[0007] The purpose of the present invention to solve the above problems is to provide a device for inspecting the status of an ultrasonic welder using a 3D scanner.

[0008] Another object of the present invention to solve the above problems is to provide a method for inspecting the status of an ultrasonic welder using a 3D scanner.

[0009] In order to achieve the above object, an ultrasonic welder condition inspection device according to one embodiment of the present invention may include a 3D scanner that scans a horn in a welding rod of an ultrasonic welder and a knurl pattern located at the end of the horn, and produces data on the height of each knurl included in the knurl pattern; and a control unit that determines the condition of the ultrasonic welder based on height data of a plurality of knurls included in the knurl pattern output from the 3D scanner.

[0010] The above 3D scanner can measure the distance to the horn as a reference point and calculate the height of each board using the distance to the horn as a reference point.

[0011] The above 3D scanner can also acquire scanned data for each laser line, perform calibration, and align the calibrated data with respect to the horn to extract a plurality of null inspection areas included in the null pattern.

[0012] Meanwhile, the condition inspection device of the ultrasonic welder may further include a first moving means for moving the welding rod or the condition inspection device. Here, the 3D scanner may acquire a plurality of image profiles for the null pattern by scanning the welding rod that is relatively moved by the first moving means.

[0013] The above 3D scanner may include a scanner body including a light projector that irradiates a laser beam and a light receiver that receives light reflected from a horn and a null pattern within the ultrasonic welder.

[0014] The above 3D scanner may further include a reflector that is positioned at a certain angle and at a certain distance from the scanner body to reflect a laser beam emitted from the light projector toward the horn and the null pattern.

[0015] The control unit determines the wear condition of the welding rod according to the height of the board, and if the number of boards having a height of the board below a preset threshold is equal to or greater than a preset number, the control unit can determine that the condition of the welding rod is poor.

[0016] The state inspection device of the ultrasonic welder may further include a second moving means for moving the welding rod or the state inspection device so that the welding rod is positioned in the space between the 3D scanner body and the reflector under the control of the control unit.

[0017] The above ultrasonic welder can be used in the assembly process during the manufacturing process of a cylindrical battery.

[0018]

[0019] A method for inspecting the condition of an ultrasonic welder according to one embodiment of the present invention for achieving the above other object is a method for inspecting the condition of an ultrasonic welder using a 3D scanner, the method including: scanning a horn in a welding rod of the ultrasonic welder and a knurl pattern located at the end of the horn; calculating data on the height of each knurl included in the knurl pattern; and determining the condition of the ultrasonic welder based on height data of a plurality of knurls included in the knurl pattern.

[0020] The step of calculating data on the height of each board included in the above board pattern may include a step of measuring the distance to the horn as a reference point and calculating the height of each board using the distance to the horn as a reference point.

[0021] The step of scanning the horn and the knurl pattern located at the end of the horn in the ultrasonic welder may include the step of obtaining a plurality of image profiles for the knurl pattern by scanning the welding rod that is relatively moved by the first moving means that moves the welding rod or the condition inspection device.

[0022] The step of scanning the horn and the knurl pattern located at the end of the horn within the ultrasonic welder may include the step of performing calibration by acquiring scanned data for each laser line irradiated by the 3D scanner; the step of aligning the calibrated data with respect to the horn; and the step of extracting a plurality of knurl inspection areas included in the knurl pattern.

[0023] The step of determining the state of the ultrasonic welder may include a step of determining the wear state of the welding rod according to the height of the board, and determining that the state of the welding rod is poor when the number of boards having a height of the board below a preset threshold is equal to or greater than a preset number.

[0024] The above 3D scanner may include a scanner body including a light projector that irradiates a laser beam and a light receiver that receives light reflected from a horn and a null pattern within the ultrasonic welder.

[0025] The above 3D scanner may further include a reflector that is positioned at a certain angle and at a certain distance from the scanner body to reflect a laser beam emitted from the light projector toward the horn and the null pattern.

[0026] The method for inspecting the condition of the ultrasonic welder may further include a step of moving the welding rod or the condition inspection device using a second moving means so that the welding rod is positioned in the space between the 3D scanner body and the reflector.

[0027] The above ultrasonic welder can be used in the assembly process during the manufacturing process of a cylindrical battery.

[0028] According to the above-described embodiment of the present invention, in order to check the degree of wear of the welding rod, the condition of the welding rod horn can be checked without having to remove the welding rod horn, thereby improving the operating efficiency of the manufacturing facility.

[0029] Additionally, by measuring the height of the board pattern using a 3D scanner, the wear level of the board can be monitored in real time. This allows for the monitoring of board wear, predicting when to replace the horn, and preventing welding defects caused by board wear.

[0030] Fig. 1 shows a side view of a welder status inspection device according to an embodiment of the present invention.

[0031] Fig. 2 is a three-dimensional diagram of a welding machine status inspection device according to an embodiment of the present invention.

[0032] FIG. 3a is a detailed drawing of a plate pattern of a welding rod that is an inspection target of an inspection device according to an embodiment of the present invention, FIG. 3b is a drawing showing the height of the plate pattern of the welding rod, and FIG. 3c is a drawing showing the distance between the lower reference surface of the horn of the welding rod and a 3D scanner.

[0033] Figure 4 is an operation flowchart of a method for inspecting the status of a welding rod according to an embodiment of the present invention.

[0034] FIG. 5 is a detailed operation flowchart of a process for calculating the height of a board in a method for inspecting the state of a welding rod according to an embodiment of the present invention.

[0035] FIG. 6a is a drawing showing a process for calculating the height of a board according to an embodiment of the present invention and the results in each detailed process, and FIG. 6b is a graph showing the calculated result data.

[0036] The present invention is susceptible to various modifications and embodiments. Specific embodiments are illustrated in the drawings and described in detail in the detailed description. However, this is not intended to limit the present invention to specific embodiments, but rather to encompass all modifications, equivalents, and alternatives falling within the spirit and technical scope of the present invention. Throughout the description of each drawing, similar reference numerals have been used to designate similar components.

[0037] Terms such as "first," "second," "A," and "B" may be used to describe various components, but these components should not be limited by these terms. These terms are used solely to distinguish one component from another. For example, without departing from the scope of the present invention, the first component could be referred to as the "second component," and similarly, the second component could also be referred to as the "first component." The term "and / or" includes any combination of multiple related items listed or any one of multiple related items listed.

[0038] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0039] The terminology used in this application is only used to describe specific embodiments and is not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the terms "comprise" or "have" indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0040] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and shall not be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0041]

[0042] Hereinafter, a preferred embodiment according to the present invention will be described in detail with reference to the attached drawings.

[0043]

[0044] Fig. 1 shows a side view of a welder status inspection device according to an embodiment of the present invention.

[0045] The welder condition inspection device according to an embodiment of the present invention may be a welder (welding rod) condition inspection device that inspects an ultrasonic welder used in a battery manufacturing process, particularly an assembly process. For example, the ultrasonic welder may be used to weld the joint between a battery's positive current collector plate and a rivet terminal of a battery can.

[0046] The welding machine condition inspection device (200) according to an embodiment of the present invention can inspect the welding rod (100) of an ultrasonic welder located between the scanner body (210) and the reflector (220) of the inspection device.

[0047] In general, ultrasonic welding is a method of welding the object by applying ultrasonic waves to the object through a conductive part, heating it with the vibration energy, and then applying appropriate pressure.

[0048] According to the embodiment illustrated in Fig. 1, the ultrasonic welding rod (100) may be configured to include a vibrator, a booster, a horn (130), etc., and may be connected to a controller (not shown) to perform welding under the control of the controller. Here, the controller converts the frequency of the input commercial power into a high frequency higher than the ultrasonic range. In addition, the vibrator (converter) converts electrical energy into mechanical energy, and the booster plays a role in amplifying the amplitude.

[0049] The horn (130) within the welding rod (100) resonates with the vibration of the vibrator and transmits vibration and load to the joining material. Here, a knurl (131) is formed on the end surface of the horn (130). Welding is performed by applying ultrasonic waves to the welding part through the horn (130) and simultaneously applying pressure to the welding part using the knurl. During the battery assembly process, the ultrasonic welding rod (100) can move downward to the location where the welding part is required in the battery being assembled and perform welding on the welding part.

[0050] A state inspection device (200) of an ultrasonic welder according to an embodiment of the present invention may be configured to include a 3D ((3 Dimension) scanner body (210) and a reflector (220) connected to one side of the scanner body.

[0051] In Fig. 1, the lower part of the reflector is connected to the lower part of the main body through a support plate, and the reflective surface of the reflector can be configured to be inclined at a certain angle with the scanner body. An ultrasonic welding rod (100) can be placed in the space formed between the scanner body (210) and the reflector (220) for inspection.

[0052] At this time, the ultrasonic welding rod (100) may be one of a plurality of ultrasonic welding rods that are attached to a rotating moving body and can be rotated. Here, a plurality of ultrasonic welding rods may be arranged and operated to increase the efficiency of the welding process. Accordingly, among the plurality of ultrasonic welding rods, there may be a welding rod that is not performing welding and is in a resting state. Accordingly, among the plurality of ultrasonic welding rods, one of the remaining ultrasonic welding rods, excluding the ultrasonic welding rod that actually performs welding, may be the inspection target according to the present invention.

[0053] Additionally, the ultrasonic welding machine condition inspection device (200) may be moved to the location where the ultrasonic welding rod (100) is positioned using a separate moving means to perform the inspection. On the other hand, the location of the ultrasonic welding machine condition inspection device (200) may be fixed, and the ultrasonic welding rod (100) may be moved to the location where the inspection device (200) is positioned to perform the inspection. In this case, a moving means that supports the movement of the ultrasonic welding rod (100) needs to be additionally configured.

[0054]

[0055] Fig. 2 is a three-dimensional diagram of a welding machine status inspection device according to an embodiment of the present invention.

[0056] Referring to FIG. 2, the ultrasonic welding machine condition inspection device (200) may be configured to include a 3D scanner body (210), a control unit (not shown), and a reflector (220) connected at a certain angle to one side of the 3D scanner body.

[0057] The 3D scanner body (210) may be configured to include a first scanner (210-1) and a second scanner (210-2). The first scanner (210-1) and the second scanner (210-2) may perform the same operation, and by synthesizing and judging the scanning results of each scanner, more accurate 3D scanning results may be obtained. The scanner according to an embodiment of the present invention may be a 3D scanner, and in particular, a laser scanner.

[0058] Non-contact scanners, commonly used in various fields, can be categorized as active and passive, depending on whether they directly illuminate the subject. Active scanners are the most common, and the term "3D scanner" is sometimes used exclusively for active scanners.

[0059] 3D scanners mainly acquire only the surface information of an object. While a camera acquires only the two-dimensional information (x, y) and color information on the surface of an object, a 3D scanner acquires the depth information (depth, z) of the object as well. The goal of a 3D scanner is to form a point cloud as a result, in which geometric information (mainly X, Y, Z) is sampled from the surface of an object. It aligns multiple scanned images of a specific part into a single coordinate system, merges them into a single data set, and derives the result.

[0060] Additionally, the 3D scanner according to an embodiment of the present invention may be, in particular, a laser scanner. Laser scanners can be categorized into various types depending on the basic scanning method and measurement method. In an embodiment of the present invention, for example, a 3D laser scanner utilizing optical triangulation may be used among laser scanners.

[0061] In the case of the optical triangulation method, a laser beam is irradiated onto the measurement target, and the height / depth of the measurement target is measured by using the image location of the light reflected from the measurement target and incident on the light receiving element.

[0062] Referring to FIG. 2, the first scanner (210-1) and the second scanner (210-2) each include a light-projecting unit (210) and a light-receiving unit (220), and the distance and angle between the light-projecting unit (210) and the light-receiving unit (220) are fixed. The light-projecting unit (210) irradiates a laser beam, and the light-receiving unit (220) receives the reflected and incident light. The inspection device (200) can obtain a difference in depth according to the relative position of the CCD (Charge Coupled Device) element of the light-receiving unit where the light is received. According to an embodiment of the present invention, a line-type laser may be used to increase the scanning speed.

[0063] Additionally, according to an embodiment of the present invention, scanning can be performed on a board located at the end of a welding rod while the welding rod is moving or while the welding rod is moving. Accordingly, the welding rod condition inspection device according to the present invention may separately include a moving means for moving the inspection device or the welding rod.

[0064] Meanwhile, the light projected through the light projector (210) is reflected by the reflector (220) that is positioned at a certain angle and at a certain distance from the first scanner (210-1) and the second scanner (210-2), so that a laser line is projected onto the measurement target. The light reflected from the measurement target is incident on the light receiver (212). Here, the reflector (220) may be, for example, a mirror, and reflects the light irradiated from the light projector (212), and the light reflected by the reflector is input to the light receiver (211).

[0065] In addition, since the relative position between the welding rod, which is the measurement target, and the laser line is moved by the first moving means, multiple image profiles of the welding rod board can be collected.

[0066] Meanwhile, the welding machine condition inspection device (200) according to an embodiment of the present invention may include a control unit (not shown) within it or may be linked to a separate control unit. The control unit may determine the condition of the ultrasonic welder based on height data of a plurality of boards included in a board pattern output from a 3D scanner.

[0067] More specifically, the control unit may determine the wear condition of the welding rod based on the height of the board, and if the number of boards whose heights are less than a preset threshold is greater than or equal to a preset number, the control unit may determine that the condition of the welding rod is poor. In addition, the control unit may calculate the average, minimum, and maximum values ​​of the height values ​​of a plurality of boards, and if each of the average, minimum, and maximum values ​​of the height values ​​is less than a predetermined threshold, the control unit may determine that the condition of the corresponding welding rod is poor.

[0068] Here, the control unit may include a processor, a central processing unit (CPU), a graphics processing unit (GPU), or a dedicated processor on which methods according to embodiments of the present invention are performed.

[0069] In addition, the welding machine condition inspection device (200) according to an embodiment of the present invention may further include a first moving means (not shown) for moving the welding rod or the condition inspection device. Accordingly, the 3D scanner can acquire multiple image profiles for the null pattern by scanning the welding rod that is relatively moved by the first moving means.

[0070] The welding machine condition inspection device (200) according to an embodiment of the present invention may further include a second moving means (not shown) that moves the welding rod or the condition inspection device so that the welding rod is positioned in the space between the 3D scanner body and the reflector under the control of the control unit.

[0071]

[0072] FIG. 3a is a detailed drawing of a plate pattern of a welding rod that is an inspection target of an inspection device according to an embodiment of the present invention, FIG. 3b is a drawing showing the height of the plate pattern of the welding rod, and FIG. 3c is a drawing showing the distance between the lower reference surface of the horn of the welding rod and a 3D scanner.

[0073] The knurl pattern (131) is fixedly attached to the body end of the horn (130) and is a means for applying pressure to the welded part and applying ultrasonic vibration by directly contacting the welded part during ultrasonic welding. Referring to FIGS. 3a and 3b, the knurl pattern (131) may be composed of a plurality of knurl regions, and each knurl region may have a pyramidal shape. The vertex of each knurl region of the pyramidal shape may have a partially cut shape, and the height of each knurl region may be measured differently depending on the degree of wear.

[0074] Referring to Fig. 3b, the height of the board (H_ Knurl ) can mean the height of the vertex (T) based on the base of the pyramid-shaped board. Therefore, in order to calculate the height of the board, it is necessary to measure the height to the base of the board, that is, the lower reference plane of the horn.

[0075] Referring to Figure 3c, the height of the horn (H_ Horn ) can be measured as the distance from the 3D scanner, which is an inspection device according to an embodiment of the present invention, to the end of the welding rod horn. Accordingly, the height of the board can be calculated by measuring the distance from the scanner to the end of the welding rod horn and the distance from the scanner to the vertex of each board, and performing a calculation between these distances.

[0076] Meanwhile, if the horn height gradually decreases or increases, regardless of whether the horn height is used to calculate the board height, there is a possibility that an abnormality has occurred in the welding electrode or at least one device associated with the welding electrode. Therefore, if an abnormality occurs in the height of the detected welding electrode horn, the inspection device according to the present invention can report the matter to the manager.

[0077]

[0078] Figure 4 is an operation flowchart of a method for inspecting the status of a welding rod according to an embodiment of the present invention.

[0079] The welding rod condition inspection method illustrated in Fig. 4 is a method of inspecting the condition of an ultrasonic welder using a 3D scanner, and can be performed by the welder condition inspection device discussed above, particularly the 3D scanner and the control unit.

[0080] The 3D scanner scans the horn and knurl pattern located at the end of the horn within the ultrasonic welder's welding rod (S300). More specifically, the 3D scanner acquires scanned data for each laser line, performs calibration, and aligns the calibrated data with respect to the horn to extract multiple knurl inspection areas included in the knurl pattern.

[0081] Additionally, the 3D scanner can acquire multiple image profiles for the null pattern by scanning a welding rod that is relatively moved by a first moving means that moves the welding rod or the condition inspection device.

[0082] Next, the 3D scanner produces data on the height of each board included in the acquired board pattern (S400). Here, the distance to the horn is measured as a reference point, and the height of each board can be produced using the measured distance to the horn as a reference point.

[0083] The control unit can determine the state of the ultrasonic welder based on the height data of a plurality of knurls included in the knurl pattern provided from the 3D scanner (S500). More specifically, according to one embodiment of the present invention, the control unit determines the wear state of the welding rod based on the height of the knurls, and if the number of knurls whose heights are less than a preset threshold is greater than or equal to a preset number, the control unit can determine that the state of the welding rod is poor. Meanwhile, according to another embodiment of the present invention, the control unit can calculate the average, minimum, and maximum values ​​of the height values ​​of a plurality of knurls, and if each of the average, minimum, and maximum values ​​of the height values ​​is less than a predetermined threshold, the control unit can determine that the state of the corresponding welding rod is poor.

[0084]

[0085] FIG. 5 is a detailed operation flowchart of a process for calculating the height of a board in a method for inspecting the state of a welding rod according to an embodiment of the present invention.

[0086] The method for inspecting the state of a welding rod according to the present invention can be performed by the welding machine state inspection device described above, particularly by a 3D scanner.

[0087] Referring to FIG. 5, the 3D scanner acquires data line by line as the welding rod passes through the scanner workspace via a moving means (e.g., a conveyor or rotary) (S510). 3D calibration is performed on the acquired data (S520).

[0088] Calibration refers to the process of converting measured coordinates into actual coordinates or into coordinates on a coordinate system appropriate for each purpose. Calibration parameters can be determined based on the internal state and installation configuration of the scanner head. Meanwhile, calibration can be performed using a calibration jig as a preliminary task before the first operation of a 3D scanner. Furthermore, if there are any changes in the reference position or status during ultrasonic welding, the 3D scanner can be recalibrated.

[0089] When the welding rod is identified in the data for which calibration is complete (S530), the data is aligned based on the horn of the welding rod. In other words, the plane is corrected based on the horn (S540). Each null area can be extracted from the aligned data (S550). When the height of the null is measured in each extracted null area (S560), the corresponding data is output (S570). Here, the output data is provided to the control unit of the inspection device, and the control unit verifies and analyzes the null height data and provides it to the facility operator or manager. If the null height data is below a preset threshold, the control unit determines that the degree of wear of the null is serious and can output a warning, notification signal, or message.

[0090] Meanwhile, if a problem occurs during the measurement process and the height of the board cannot be measured properly, a measurement error is reported (S571).

[0091]

[0092] FIG. 6a is a drawing showing a process for calculating the height of a board according to an embodiment of the present invention and the results in each detailed process, and FIG. 6b is a graph showing the calculated result data.

[0093] Referring to Fig. 6a, when a 3D image profile of a horn, which is a measurement point in a welding rod, is acquired by a 3D scanner, calibration is performed on the acquired 3D data. Subsequently, when the plane is calibrated based on the horn, it can be confirmed that each null region within the null pattern is clearly revealed. Each null region is then extracted, and the null height value for each null region is calculated as the result data.

[0094] In the result data graph of Fig. 6b, A, B, C, D, and E represent lines for each null, and are used together with numbers to represent each null area. The height values ​​of each null, which are the result values ​​(null height values ​​in A3, B2, B3, B4, C1, C2, C3, C4, C5, D2, D3, D4, and E3), can be confirmed through the bar graph at the bottom of the graph of Fig. 6b and the height values ​​displayed on the right.

[0095]

[0096] According to the embodiment of the present invention as described above, in order to check the degree of wear of the welding rod, the condition of the welding rod horn can be checked without having to remove the welding rod horn, thereby improving the operating efficiency of the manufacturing facility.

[0097] Additionally, by measuring the height of the board pattern using a 3D scanner, the wear level of the board can be monitored in real time. This allows for the monitoring of board wear, predicting when to replace the horn, and preventing welding defects caused by board wear.

[0098]

[0099] The operations of the method according to an embodiment of the present invention can be implemented as a computer-readable program or code on a computer-readable recording medium. A computer-readable recording medium includes any type of recording device that stores data readable by a computer system. Furthermore, a computer-readable recording medium can be distributed across network-connected computer systems, allowing the computer-readable program or code to be stored and executed in a distributed manner.

[0100] While some aspects of the present invention have been described in the context of a device, they may also represent a description of a corresponding method, wherein a block or device corresponds to a method step or a feature of a method step. Similarly, aspects described in the context of a method may also be described as a corresponding block or item or a feature of a corresponding device. Some or all of the method steps may be performed by (or using) a hardware device, such as, for example, a microprocessor, a programmable computer, or an electronic circuit. In some embodiments, one or more of the most significant method steps may be performed by such a device.

[0101] Although the present invention has been described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention as set forth in the claims below.

Claims

1. A 3D (3 Dimension) scanner that scans the horn inside the welding rod of the ultrasonic welder and the knurl pattern located at the end of the horn, and produces data on the height of each knurl included in the knurl pattern; and An ultrasonic welder condition inspection device, comprising a control unit that determines the condition of the ultrasonic welder based on height data of a plurality of boards included in the board pattern output from the 3D scanner.

2. In claim 1, The above 3D scanner, A device for inspecting the condition of an ultrasonic welder, which measures the distance to the horn as a reference point and calculates the height of each board as a reference point.

3. In claim 1, The above 3D scanner, A device for inspecting the condition of an ultrasonic welder, which acquires scanned data by laser line, performs calibration, aligns the calibrated data based on the horn, and extracts a plurality of null inspection areas included in the null pattern.

4. In claim 1, Further comprising a first moving means for moving the welding rod or the condition inspection device, The above 3D scanner is a device for inspecting the condition of an ultrasonic welder, which obtains multiple image profiles for the null pattern by scanning the welding rod that moves relatively by the first moving means.

5. In claim 1, The above 3D scanner, a light emitting unit for irradiating a laser beam; and A device for inspecting the condition of an ultrasonic welder, comprising a scanner body including a light receiving unit that receives light reflected and incident on the horn and null patterns.

6. In claim 5, The above 3D scanner, An ultrasonic welding machine condition inspection device further comprising a reflector that is arranged at a predetermined angle and a predetermined distance from the scanner body to reflect a laser beam irradiated from the light projector toward the horn and the null pattern.

7. In claim 1, The above control unit, The wear condition of the welding rod is judged based on the height of the above board. A device for inspecting the condition of an ultrasonic welder, which determines that the condition of the welding rod is poor when the number of boards whose height is less than a preset threshold is greater than or equal to a preset number.

8. In claim 6, A state inspection device for an ultrasonic welder, further comprising a second moving means for moving the welding rod or the state inspection device so that the welding rod is positioned in the space between the 3D scanner body and the reflector under the control of the control unit.

9. In claim 1, The above ultrasonic welder, A device for inspecting the condition of an ultrasonic welder used in the assembly process during the manufacturing process of cylindrical batteries.

10. A method for inspecting the condition of an ultrasonic welder using a 3D scanner, A step of scanning a horn within a welding rod of the ultrasonic welder and a knurl pattern located at the end of the horn; A step of producing data on the height of each board included in the above board pattern; and A method for inspecting the condition of an ultrasonic welder, comprising a step of determining the condition of the ultrasonic welder based on height data of a plurality of boards included in the board pattern.

11. In claim 10, The step of producing data on the height of each board included in the above board pattern is: A method for inspecting the condition of an ultrasonic welder, comprising the steps of measuring the distance to the horn as a reference point and calculating the height of each board as a reference point.

12. In claim 10, The step of scanning the above horn and the null pattern located at the end of the above horn is: A method for inspecting the condition of an ultrasonic welder, comprising the step of obtaining a plurality of image profiles for the null pattern by scanning the welding rod that is relatively moved by a first moving means that moves the welding rod or the condition inspection device.

13. In claim 10, The step of scanning the above horn and the null pattern located at the end of the above horn is: A step of performing calibration by acquiring scanned data for each laser line investigated by the above 3D scanner; A step of aligning the calibrated data based on the above horn; and A method for inspecting the condition of an ultrasonic welder, comprising the step of extracting a plurality of null inspection areas included in the above null pattern.

14. In claim 10, The step of judging the status of the above ultrasonic welder is: A method for inspecting the condition of an ultrasonic welder, comprising the step of determining the wear condition of the welding rod according to the height of the board, and determining that the condition of the welding rod is poor if the number of boards having a height of the board below a preset threshold is equal to or greater than a preset number.

15. In claim 10, The above 3D scanner, A method for inspecting the condition of an ultrasonic welder, comprising a scanner body including a light projector that irradiates a laser beam and a light receiver that receives light reflected and incident on a horn and null pattern within the ultrasonic welder.

16. In claim 15, The above 3D scanner, A method for inspecting the condition of an ultrasonic welder, further comprising a reflector that is arranged at a predetermined angle and a predetermined distance from the scanner body to reflect a laser beam irradiated from the light projector toward the horn and the null pattern.

17. In claim 16, A method for inspecting the condition of an ultrasonic welder, further comprising the step of moving the welding rod or the condition inspection device using a second moving means so that the welding rod is positioned in the space between the 3D scanner body and the reflector.

18. In claim 10, The above ultrasonic welder, A method for inspecting the condition of an ultrasonic welder used in an assembly process during the manufacturing process of a cylindrical battery.

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