Busbar Laser Welding Head With Spring Pressure and Beam Aperture
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Solution Overview
Problem
Existing welding techniques for connecting busbars to battery cells in energy storing systems face challenges in applying pressure uniformly and efficiently while ensuring precise laser welding, particularly for cylindrical battery cells with accessible poles, and require multiple welds per pole region, impacting productivity.
Innovation Solution
A laser welding system with a resilient member and pressing elements, such as helical springs, applies pressure to busbar pole regions using a scanning head and robot arm, allowing simultaneous or sequential welding of multiple pole regions without moving the end effector, and includes a thermally and electrically insulating pressing element to manage heat and electrical interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied to ensure good contact between pole region and pole during laser welding, then welding quality is improved, but the pressing mechanism may interfere with the laser beam path
Solution Approach 1:
A pressing element is introduced as an intermediary component between the pole region and the pole. This pressing element is specifically designed with a laser aperture that allows the laser beam to pass through while the pressing element itself applies the necessary mechanical pressure to ensure good contact between the pole region and the pole during welding.
Solution Approach 2:
The pressing mechanism is segmented into distinct functional components: a pressing element with a laser aperture, a resilient member for applying pressure, and a robot for positioning. This segmentation allows each component to perform its specific function independently, with the laser aperture ensuring the beam path remains unobstructed while the pressing element applies pressure.
2Manufacturing precision
If multiple independent welds are performed one by one, then welding precision is maintained, but productivity is reduced due to sequential operation
Solution Approach 1:
Multiple welding operations are merged into a single coordinated process. The pressing element is designed with multiple pressing points that can simultaneously press multiple pole regions against corresponding poles, while the robot moves the pressing element to different positions to perform multiple welds without requiring separate pressing mechanisms for each weld location.
Solution Approach 2:
The system transitions from static, fixed pressing mechanisms to a dynamic robot-controlled pressing element that can adaptively position and press at multiple locations. The robot dynamically moves the pressing element to different pole regions while maintaining consistent pressing force, enabling efficient sequential or simultaneous welding operations.
3Reliability
If battery cells are kept charged during welding operation, then battery functionality is maintained, but safety risks increase due to heat and electrical interference
Solution Approach 1:
A thermally insulating pressing element is introduced as an intermediary between the laser welding zone and the battery components. This pressing element is specifically designed with thermal insulation properties that block heat transmission from the laser welding area to the battery poles and surrounding components, thereby reducing thermal risks while allowing the battery to remain charged during welding.
Solution Approach 2:
The pressing element creates a protective interface that isolates the battery components from the high-temperature welding environment. By using materials with low thermal conductivity and appropriate electrical insulation properties, the pressing element effectively creates a thermal and electrical barrier that protects the battery while allowing the welding process to proceed.
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 system enhances productivity by reducing assembly time and ensuring clean, resistant welds with improved precision and efficiency, accommodating variations in pole heights and maintaining battery functionality during welding.
Implementation Method 1
a resilient member having a first end mounted to the body and a second end opposite the first end, a pressing element at the second end of the resilient member
Implementation Method 2
laser welding system for welding pole regions of a busbar to electrical poles of a battery module with a laser beam
Implementation Method 3
Welding pole regions of the busbar to poles of the battery cells using a laser
Implementation Method 4
a thermally and electrically insulating pressing element to manage heat and electrical interference
Implementation Method 5
a thermally and electrically insulating pressing element to manage heat and electrical interference
Data Source
AI summary
The laser welding system can have: a laser welder having an emitter configured to emit the laser beam, and a scanning head optically coupled to the laser emitter; a robot having an end effector having a body, a resilient member having a first end mounted to the body and a second end opposite the first end, a pressing element at the second end of the resilient member, and a laser aperture extending across the body, the resilient member and the pressing element; and wherein the laser beam can be directed across the laser aperture by the scanning head when either one of the pole regions is pressed against a corresponding one of the electrical poles by the pressing element.