Laser Welding Jig With Tilting Contact Member
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Solution Overview
Problem
Conventional laser welding jigs struggle to maintain adhesion between cell leads and the welding surface due to variations in cell size and module assembly deviations, leading to gaps and defects in the welding pattern.
Innovation Solution
A jig assembly with a tilting unit and elastic member that allows the contact member to tilt and adhere elastically to the cell leads, ensuring consistent contact and compensating for height deviations, combined with a displacement sensor to adjust the focal length of the laser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional rigid welding jig is used, then the structure is simple and easy to manufacture, but it cannot adapt to height variations of cell leads caused by cell size variation and module assembly deviation
Solution Approach 1:
The welding jig employs a tilting unit with a hinge structure that enables the contact member to dynamically adjust its angle relative to the jig body. This dynamic mechanism allows the contact member to adapt to height variations in cell leads while maintaining welding pressure, resolving the contradiction between adaptability and structural simplicity.
Solution Approach 2:
The welding jig is divided into separable components: a jig body and a contact member connected by a tilting unit. This segmentation allows the contact member to independently adjust its position and angle, providing adaptability to height variations without requiring complete redesign of the entire jig structure.
2Manufacturing precision
If the contact member is made rigid to maintain stable contact, then the welding pressure is consistent, but it cannot compensate for focal length changes due to height deviation
Solution Approach 1:
A displacement sensor detects the actual position of the cell lead surface and provides feedback to a control unit. The control unit adjusts the focal length of the laser based on this feedback, ensuring welding quality is maintained despite height deviations. This feedback mechanism resolves the contradiction between maintaining stable contact and compensating for height variation.
Solution Approach 2:
The system dynamically changes the focal length parameter of the laser based on detected height deviations. By adjusting this critical parameter, the system maintains welding quality even when the contact member position varies due to cell lead height differences.
3Manufacturing precision
If the laser focal length is fixed, then the welding process is simple and fast, but it cannot accommodate height deviations of cell leads
Solution Approach 1:
The displacement sensor and control unit form a feedback system that automatically adjusts the laser focal length based on real-time measurement of cell lead height. This automated feedback mechanism achieves welding precision without requiring complex manual adjustment procedures.
Solution Approach 2:
The system performs self-adjustment of the focal length based on sensor input, eliminating the need for operator intervention. This self-service capability maintains welding precision while keeping the overall process relatively simple and automated.
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 solution maintains adhesion and prevents defects in the welding pattern by ensuring consistent contact and adjusting for height variations, thereby improving welding quality and uniformity.
Implementation Method 1
an elastic member interposed between the jig body and the contact member to give an elastic force for closely adhering the contact member to the welding target
Implementation Method 2
a laser for welding is capable of passing through a first penetration portion formed through the jig body
Implementation Method 3
the bent portions of the cell leads 20 are fused by a laser L outputted from a laser generator S
Data Source
AI summary
A jig assembly for laser welding includes a jig body having a first penetration portion through which laser light for welding is capable of passing; a contact member connected to the jig body to contact a welding target, the contact member having a second penetration portion through which the laser light passing through the first penetration portion is capable of passing toward the welding target; a tilting unit having a hinge structure to connect the jig body and the contact member to each other; and an elastic member interposed between the jig body and the contact member to apply an elastic force to provide close contact between the contact member and the welding target.