Battery Cell End Cap Welding with Opposed Dual Heads
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Solution Overview
Problem
The efficiency of welding between the end cap and the housing in battery production is low, failing to meet the higher production efficiency requirements of the rapidly developing battery industry.
Innovation Solution
A welding method and apparatus that utilize a first and second welding head to weld the housing from two opposite sides of the end cap respectively, and a jig is placed in a first welding station to weld the target weld zone sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed around the entire end cap circumference, then complete sealing is achieved, but welding time is excessive and efficiency is low
Solution Approach 1:
The welding process is divided into multiple discrete welding sections around the end cap circumference. Instead of continuous welding, the welding head performs sequential welding in segmented zones, reducing total welding time while maintaining sealing integrity through targeted welding at critical locations.
Solution Approach 2:
The patent applies welding to only the necessary portions of the end cap circumference rather than the entire perimeter. By identifying and welding only the critical sealing zones, the process achieves adequate sealing quality with reduced welding time and improved efficiency.
2Productivity
If a single welding head is used to weld around the end cap, then equipment complexity is low, but welding time is excessive
Solution Approach 1:
Multiple welding heads are combined into a single integrated welding apparatus that can simultaneously perform welding operations at different locations around the end cap. This merging of multiple welding functions into one device increases welding efficiency while managing equipment complexity through integration.
Solution Approach 2:
The welding apparatus transitions from a single-point welding approach to a multi-point simultaneous welding capability by adding spatial dimensions to the welding process. Multiple welding heads operate at different angular positions around the end cap, performing welding in parallel to reduce total process time.
3Productivity
If welding is performed sequentially on different sides of the end cap, then equipment simplicity is maintained, but total welding time increases
Solution Approach 1:
The welding apparatus is pre-configured with multiple welding heads positioned at predetermined locations around the end cap before the welding process begins. This preliminary positioning allows simultaneous welding operations to start immediately without sequential setup, improving efficiency while keeping the overall system configuration manageable.
Data Source
AI summary
A welding method includes placing a housing covered with an end cap into a jig, where a clearance structure is created on the jig and available for exposing a target weld zone between the end cap and the housing, and the target weld zone includes a first target weld zone section and a second target weld zone section located on two opposite sides of the end cap respectively; and moving the jig to a first welding station of a welding device; welding, by a first welding head of the welding device, the first target weld zone section through the clearance structure; and welding, by a second welding head of the welding device, the second target weld zone section through the clearance structure. The first welding station is located between the first welding head and the second welding head.