Busbar Weld Quality Detection Using Contact Temperature Sensors
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Solution Overview
Problem
Defining the quality of busbar weldings is difficult and burdensome, especially with reflective surfaces, as existing methods like thermal cameras can be unreliable, potentially leading to battery failure due to poor weldings causing increased resistance and voltage drop.
Innovation Solution
A method and arrangement using a holder with temperature sensors arranged according to welding spots, applying a contacting force to measure temperature responses, which allows for quick and reliable assessment of welding quality, even on glossy or reflective busbars, by heating the busbar and analyzing temperature changes with a data managing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal cameras are used to define welding quality, then measurement can be performed remotely, but the measurements are unreliable due to reflective surfaces of busbars
Solution Approach 1:
The patent introduces temperature sensors as intermediary devices that physically contact the busbar at measuring spots to directly measure temperature. This mediator approach bypasses the reflective surface problem of thermal cameras by using contact-based measurement, thereby improving measurement reliability while maintaining operational efficiency
Solution Approach 2:
The patent replaces the optical measurement system (thermal camera) with a thermal conduction-based measurement system (contact temperature sensors). This substitution eliminates the interference caused by reflective surfaces by using direct thermal contact to measure temperature at welding spots
2Measurement precision
If traditional welding quality definition methods are used, then measurement can be performed, but the process is difficult and burdensome
Solution Approach 1:
The patent divides the busbar into multiple measuring spots, each with dedicated temperature sensors arranged in a predetermined pattern. This segmentation allows independent measurement at each welding location, simplifying the overall measurement process while maintaining comprehensive coverage and precision
Solution Approach 2:
The patent changes the measurement parameter from visual/optical inspection to direct temperature measurement. By measuring temperature response at specific spots during controlled heating, the system transforms a complex quality assessment into a straightforward thermal response evaluation
3Reliability
If contact temperature sensors are used to measure welding quality, then measurement reliability is improved, but the contacting force may cause movement or bending of the busbar
Solution Approach 1:
The patent applies a limited contacting force that is sufficient to ensure good thermal contact between sensors and busbar surface, but controlled to be below the threshold that would cause busbar movement or bending. This partial action approach achieves measurement reliability without compromising structural stability
Solution Approach 2:
The patent implements force limiting devices on temperature sensors before measurement begins. This pre-established force constraint prevents excessive contacting force from causing busbar displacement, ensuring both measurement reliability and structural stability throughout the measurement process
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 provides a quick and reliable method to assess busbar welding quality, reducing measurement errors and identifying potential malfunctions, ensuring accurate and efficient battery manufacturing by determining temperature responses and internal resistance values.
Implementation Method 1
measuring temperatures of the measuring spots with the temperature sensors, creating a measuring spot specific temperature response based on temperatures measured in the corresponding measuring spot
Implementation Method 2
heating up the busbar
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method and an arrangement for defining the quality of busbar weldings, the method comprising - providing (500) a holder (1) that comprises a set of temperature sensors (2). The temperature sensors (2) being arranged to a predetermined pattern (3) according to the welding spots (4) in the busbar (5). Placing (501) the holder (1) on the busbar (5) welded to terminals (6) of battery cells and pressing (502) the temperature sensors (2) by a contacting force against the busbar (5) so that they make a contact with the busbar (5) in measuring spots (7), heating up (503) the busbar (5), measuring (504) temperatures of the measuring spots (7) with the temperature sensors (2), creating (505) a measuring spot specific temperature response based on temperatures measured in the corresponding measuring spot, and defining (506) the welding quality of the welding spot (4) based on the measuring spot specific temperature response of the nearest measuring spot (7).