Laser Galvanometer Ranging for Battery Post Welding Alignment
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Solution Overview
Problem
Inappropriate distance between a laser galvanometer and a post during the welding of battery product components leads to poor welding quality, affecting product yield.
Innovation Solution
A welding system and method that utilizes a rangefinder to measure distances between posts in a battery product, determining pre-weld ranging parameters, and adjusting the laser galvanometer's position based on these measurements, with a human-machine interface displaying these parameters for user control and verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the laser galvanometer and the post is not properly controlled, then the welding process can be performed, but the welding quality deteriorates
Solution Approach 1:
The system performs pre-weld ranging to measure the distance between the laser galvanometer and the post before the welding operation. This preliminary measurement allows the system to determine whether the distance is within the required range and to adjust the laser galvanometer's position in advance, ensuring optimal welding quality before the actual welding process begins.
Solution Approach 2:
The system implements a feedback mechanism where the pre-weld ranging result is used to control the position of the laser galvanometer. The controller receives the distance measurement, compares it with the preset range, and automatically adjusts the laser galvanometer's position accordingly. This closed-loop feedback ensures that the welding is always performed at the optimal distance, maintaining high welding quality.
2Manufacturing precision
If pre-weld ranging and parameter verification are implemented, then welding quality improves, but the operation time increases
Solution Approach 1:
The pre-weld ranging and parameter verification are performed as preliminary actions before the actual welding process. By completing these preparatory steps in advance, the system ensures that subsequent welding operations can proceed efficiently without interruptions for adjustments or quality checks, thereby minimizing the overall time loss.
Solution Approach 2:
The system performs self-verification of welding parameters through automatic ranging and comparison with preset ranges. This self-service capability eliminates the need for manual measurement and adjustment by operators, automating the quality control process and reducing the time required for these operations.
3Adaptability or versatility
If the laser galvanometer position is fixed, then the device structure is simple, but it cannot adapt to different post positions affecting welding quality
Solution Approach 1:
The system transitions from a fixed laser galvanometer position to a dynamic, adjustable position system. The laser galvanometer can be automatically repositioned based on the measured distance to the post, allowing the system to adapt to different post positions while maintaining optimal welding parameters. This dynamic adjustment capability enhances versatility without requiring complex mechanical structures.
Solution Approach 2:
The system replaces complex mechanical positioning mechanisms with a combination of optical ranging (laser) and electronic control. Instead of using elaborate mechanical systems to physically adjust the laser galvanometer position, the invention uses laser-based distance measurement combined with electronic actuation, simplifying the overall device structure while achieving the required adaptability.
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
Improves welding quality and increases product yield by ensuring precise alignment and distance management between the laser galvanometer and posts, facilitating intuitive user control through the human-machine interface.
Implementation Method 1
perform ranging of the at least two posts along a first direction using the rangefinder, to obtain the set of ranging values, the first direction being parallel to an optical axis of a laser galvanometer
Data Source
AI summary
Provided are a welding system and a spot check method for a welding system. The welding system includes a controller, a human-machine interface, and a welding device. The spot check method for a welding system includes: controlling a rangefinder in a welding device to perform ranging, along a first direction, of at least two posts in a battery product to be welded, so as to obtain a set of ranging values between the at least two posts and the rangefinder, the first direction being parallel to an optical axis of a laser galvanometer in the welding device, the rangefinder being calibrated based on a first position in the first direction, the first position being a position of a focal point of the laser galvanometer in the first direction, and the rangefinder being at a fixed distance from the laser galvanometer in the first direction.