Battery Busbar Welding Alignment Using Location Hole Referencing
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Solution Overview
Problem
In battery manufacturing, existing technologies lack effective methods for detecting welding deviations in bus assemblies and poles, which affects safety performance and welding quality, with a focus on improving accuracy and monitoring welding quality rather than just positioning.
Innovation Solution
A welding deviation detection device comprising a pre-welding addressing mechanism, a welding mechanism, and a post-welding detection mechanism, which determines relative position relations between location holes and poles, accurately welds the bus assembly, and detects welding deviations by comparing the positions of welds and location holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If welding position accuracy is improved through positioning methods, then welding precision is improved, but welding quality detection capability remains insufficient
Solution Approach 1:
The patent applies preliminary action by establishing the relative position relationship between location holes and poles before the welding process. The pre-welding detection mechanism captures images of location holes to determine their positions and calculates relative position relationships, which are then stored for use during welding and post-welding detection. This preliminary establishment of positional data enables both precise welding positioning and subsequent welding quality detection without requiring separate measurement systems.
2Measurement precision
If a post-welding detection mechanism is added to detect welding deviations, then welding quality monitoring is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a detection mechanism that serves multiple functions: it detects location hole positions for welding positioning, detects weld positions after welding, and calculates welding deviations by comparing these positions. The same detection mechanism and processing logic are used throughout the welding process, eliminating the need for separate detection systems for each function and reducing overall device complexity.
Solution Approach 2:
The patent applies copying by using image capture to create visual copies of the location holes and weld positions. The detection mechanism captures images of the location holes before welding and images of the welds after welding, then processes these image copies to determine positions and calculate deviations. This non-contact optical copying method simplifies the detection system compared to physical measurement devices.
3Manufacturing precision
If relative position relationships are determined and stored for both welding and detection, then welding accuracy and detection accuracy are improved, but information processing requirements increase
Solution Approach 1:
The patent applies preliminary action by calculating and storing the relative position relationships between location holes and poles before welding occurs. This pre-calculated positional data is saved in memory and reused during both the welding process and post-welding detection, eliminating the need to recalculate these relationships and reducing real-time data processing requirements.
Data Source
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AI summary
A welding deviation detection device includes a pre-welding addressing mechanism (4) that can determine relative position relations between location holes (131) and a plurality of poles (121a) in a battery 1, and send the relative position relations to a welding mechanism (5) and a post-welding detection mechanism (6); the welding mechanism (5) that can detect first positions of the location holes (131), and determine first positions of the plurality of poles (121a) based on the first positions of the location holes (131) and the relative position relation, so that the welding mechanism (5) can accurately weld a bus assembly (14) to the plurality of poles (121a) based on the first positions of the plurality of poles (121a) to form a plurality of welds; and the post-welding detection mechanism (6) that can detect second positions of the location holes (131) and positions of the plurality of welds, and detect welding deviation situations of the bus assembly (14) and the poles (121a) based on the second positions of the location holes (131), the positions of the plurality of welds and the relative position relations. The bus assembly (14) and the plurality of poles (121a) can be welded accurately through the welding mechanism (5), and the welding deviation situations can be detected simply, conveniently and timely through the post-welding detection mechanism (6). In addition, a welding deviation detection method, a battery and a power utilization device are also provided.