Battery Electrode Welding With Real-Time Weld Pool Feedback
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Solution Overview
Problem
Existing methods for welding electrodes in batteries, such as laser and ultrasonic welding, often result in welds with high electrical resistance and low mechanical resistance, which can lead to power losses and mechanical failure under stress, particularly in automotive applications.
Innovation Solution
A method using a welding unit with a joining device, emitter device, video camera, and processing device to control the welding process by adjusting heat and pressure based on real-time temperature and electrical resistance measurements, ensuring optimal weld pool formation and size, and using either laser or ultrasonic technology to achieve low electrical resistance and high mechanical resistance welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding or ultrasonic welding is used to connect electrodes, then welding speed and automation are improved, but the weld quality deteriorates with high electrical resistance and low mechanical resistance
Solution Approach 1:
The patent implements real-time monitoring of welding parameters (temperature, electrical resistance, weld pool geometry) and uses this feedback to dynamically adjust welding parameters. Sensors measure the actual welding state and feed this information back to the control system, which then modifies laser power, welding speed, or other parameters to maintain optimal weld quality while preserving high welding speed and automation.
Solution Approach 2:
The patent dynamically changes welding parameters (laser power, welding speed, focal position, gas flow rate) based on real-time measurements of temperature, electrical resistance, and weld pool characteristics. This continuous parameter adjustment ensures optimal weld quality is achieved while maintaining high productivity through automated control.
2Reliability
If real-time monitoring and control of welding parameters is implemented, then weld quality is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses sensors to monitor welding parameters in real-time and feeds this information back to the control system. This feedback mechanism enables automated adjustment of welding parameters to maintain optimal weld quality without requiring complex manual intervention systems.
Solution Approach 2:
The welding system performs self-diagnosis and self-adjustment by automatically monitoring its own parameters and correcting deviations from optimal welding conditions. The system uses real-time data from sensors to autonomously optimize weld quality without external intervention, reducing the need for complex external control systems.
3Reliability
If real-time monitoring of temperature and electrical resistance is performed, then welding errors can be corrected, but measurement precision requirements and cost increase
Solution Approach 1:
The patent implements monitoring of temperature and electrical resistance during welding, using this feedback to detect and correct welding errors in real-time. The control system compares measured parameters against target values and automatically adjusts welding parameters to correct deviations, ensuring consistent weld quality.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with electrical and optical sensing methods. Electrical resistance measurements and optical monitoring of weld pool geometry provide precise feedback on welding quality without requiring complex mechanical measurement apparatus, reducing overall system complexity while maintaining measurement accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures high-quality welds with low electrical resistance and high mechanical resistance, allowing for real-time correction of errors and cost-effective implementation using commercially available components.
Implementation Method 1
a laser beam is focussed on one of the two electrodes (3) to be joined and is progressively shifted so as to move along at least one heating line
Implementation Method 2
The laser beam emitted by the emitter device (9) provides a concentrated source of heat and thus causes a localized heating of the electrodes (3)
Implementation Method 3
causes a localized heating of the electrodes (3) for locally causing a melting of the metal making up the electrodes (3) so as to generate a weld pool (10)
Implementation Method 4
a video camera (11) which is arranged to frame the area in which the weld pool (10) is generated and is thus configured to capture a series of digital images of the weld pool (10) during the heating
Implementation Method 5
a processing device (12) which is configured to analyse the digital images so as to determine a value of at least one parameter of the welding process
Implementation Method 6
The connections of the electrodes of the cells (both with other electrodes and with connecting bars) are normally carried out by means of a welding process that can use the laser welding technology
Implementation Method 7
locally causing a melting of the metal making up the electrodes (3) so as to generate a weld pool (10)
Data Source
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AI summary
A method to execute a weld of an electrode (3) of a cell (2) which is part of a battery (1) and having the steps of: causing the electrode (3) to come into contact with another element to which the electrode (3) must be welded; locally heating the electrode (3) and the other element so as to locally cause a melting of the metal making up the electrode (3) and of the metal making up the other element in order to generate a weld pool (10); waiting for the weld pool (10) to cool down, thus giving stability to the weld; capturing, by means of a video camera (11), a series of digital images of the weld pool (10) during the heating; analysing the digital images in order to determine a value of at least one parameter of the welding process; and changing the execution of the melting process based on the value of the parameter.