Infrared Weld Signal Detection for Poor Battery Welding
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Solution Overview
Problem
The challenge in the 3C field is to identify poor welding in metal-sheet laser welding, as visual inspection is insufficient to determine welding defects, which can lead to unstable electrical contact in batteries.
Innovation Solution
A method using an industrial personal computer (IPC) to detect poor welding by obtaining an electrical signal corresponding to an infrared light signal generated by a target weld after the weld is complete, and determining the presence of poor welding based on this signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection is used to check weld quality, then the inspection process is simple and fast, but poor welding cannot be identified accurately
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system using an infrared sensor to capture thermal radiation signals from the weld area. This substitution enables objective, quantitative measurement of weld quality based on temperature distribution, eliminating the subjectivity and limitations of human visual inspection while maintaining operational simplicity through automated analysis algorithms.
Solution Approach 2:
The patent introduces an infrared sensor as an intermediary device that indirectly measures weld quality by detecting thermal radiation patterns. Instead of directly observing weld appearance, the system uses temperature field distribution as a mediator to infer welding defects, enabling detection of poor welding through thermal characteristics rather than direct visual examination.
2Productivity
If laser welding is performed on sheet materials, then welding speed is high and productivity is improved, but poor welding defects occur that are difficult to detect
Solution Approach 1:
The patent implements a feedback mechanism by continuously monitoring the temperature field distribution during and after laser welding using an infrared sensor. The system captures thermal radiation signals, analyzes temperature patterns, and provides real-time feedback on weld quality. When poor welding is detected through abnormal temperature distribution, the system can trigger alerts or automatic corrections, ensuring consistent weld quality despite high welding speeds.
3Reliability
If simple visual inspection is used, then the detection method is easy to operate, but welding defects cannot be reliably identified
Solution Approach 1:
The patent enables the detection system to perform self-analysis by automatically processing infrared images and temperature data through built-in algorithms. The system independently identifies thermal patterns indicative of poor welding, calculates quality metrics, and generates detection results without requiring complex manual intervention. This self-service capability maintains operational simplicity while achieving reliable defect identification through automated thermal analysis.
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 method allows for accurate detection of poor welding, ensuring continuous and stable electrical contact in batteries, and enables automatic repair welding by transmitting position information to the laser welding system.
Implementation Method 1
a sensor module...configured to obtain an infrared light signal generated by the weld
Data Source
AI summary
A method for detecting poor welding in welding and a related device are provided. The method includes the following. An industrial personal computer (IPC) obtains an electrical signal corresponding to an infrared light signal generated by a target weld in a first period. A start moment of the first period is not earlier than a moment at which the complete target weld is formed. The IPC determines whether the target weld has poor welding according to the electrical signal corresponding to the infrared light signal.