Battery Component Scanner Welding With Coaxial OCT Control

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Solution Overview

Problem

Existing laser welding methods for battery covers require complex apparatus and high cycle times due to the need for relative movement between the laser processing head and battery components, resulting in inefficiencies and potential weld quality issues.

Innovation Solution

The method employs scanner welding with an OCT sensor system, guiding a measurement beam coaxially with the processing beam at a matching angle of incidence, allowing for dynamic and precise welding without moving the laser processing head or components, and using an OCT sensor for real-time process control to maintain uniform weld quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If relative movement between laser processing head and battery components is used to achieve orthogonal incidence, then uniform welding depth and weld seam quality are improved, but apparatus complexity and cycle time increase

Engineering Contradiction:

Improvewelding depth uniformityVSAvoidapparatus structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of moving the laser processing head relative to the battery components (conventional approach), the patent inverts the approach by keeping the laser processing head stationary and moving the battery components through the laser beam. This inversion eliminates the need for complex positioning systems on the laser head while achieving the same welding quality through the opposite motion configuration.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical movement system of the laser processing head with a stationary optical scanning system. The laser beam is directed onto different positions of the battery components through optical scanning mirrors or galvanometers, substituting mechanical head movement with optical beam steering, thereby simplifying the apparatus structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If relative movement between laser processing head and battery components is used, then orthogonal incidence is achieved, but cycle time increases due to acceleration and deceleration

Engineering Contradiction:

Improveangle of incidence uniformityVSAvoidwelding cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent inverts the motion configuration by keeping the laser processing head stationary and moving the battery components instead. This eliminates the repeated acceleration and deceleration of the laser head, reducing cycle time while maintaining orthogonal incidence through the inverted motion system.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

By keeping the laser processing head stationary and using continuous optical scanning to direct the beam across the battery components, the patent enables continuous welding action without the interruptions caused by accelerating and decelerating a heavy laser head, thereby reducing cycle time and improving productivity.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If laser processing head is moved relative to battery components, then orthogonal incidence is maintained, but weld seam rounding increases

Engineering Contradiction:

Improveincidence angle consistencyVSAvoidweld seam profile

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent inverts the motion system so that battery components move through a stationary laser processing head. This inversion provides more stable incidence angle control and reduces weld seam rounding by eliminating the dynamic positioning variations associated with moving the laser head during welding.

Inventive Principle:

Principle #13The other way round (Inversion)

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

This approach eliminates the need for complex apparatus and reduces cycle times while ensuring high weld quality and gastightness of the battery, with the OCT sensor system providing accurate monitoring and control of the welding depth and seam quality.

Implementation Method 1

a measurement beam of an OCT sensor system being guided optically coaxially with the processing beam

Methodology Applied

Scientific EffectOptical Coherence Tomography (OCT): Tomography

Implementation Method 2

welding the two components to one another by scanner welding using a processing beam provided by a welding apparatus

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS20240383068A1Method for joining two components of a battery by means of scanner welding

Publication Date: 2024.11.21 TRUMPF LASER & SYSTEMTECHNIK GMBH

AI summary

A method for joining two components of a battery includes welding the two components to one another by scanner welding using a processing beam provided by a welding apparatus, and guiding a measurement beam of an OCT sensor system optically coaxially with the processing beam while the welding apparatus is performing the scanner welding. The measurement beam and the processing beam are guided at a substantially matching angle of incidence relative to at least one processing surface of the two components.