Rotary Battery Laser Welding for Continuous End-Cover Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing welding devices for cylindrical battery end covers in the lithium battery industry face inefficiencies due to intermittent welding methods that require mechanical positioning before each cycle, preventing simultaneous welding and battery movement, which fails to meet high-speed production line demands.
Innovation Solution
A welding device with a rotating assembly and a fixing assembly that allows the battery to rotate while being welded, using a laser welding device with a galvanometer unit to deflect the laser, enabling continuous motion through welding, unloading, and loading zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If intermittent welding method is used with mechanical positioning before each cycle, then welding precision can be maintained, but production efficiency deteriorates due to extended takt time
Solution Approach 1:
The patent implements a dynamic positioning system where the battery and welding head move simultaneously at synchronized speeds. The battery is fed continuously through a feeding mechanism while the welding head tracks along with it, eliminating static positioning cycles. This dynamic approach maintains welding precision through real-time tracking while enabling continuous production flow, thereby resolving the contradiction between precision and efficiency
Solution Approach 2:
The patent applies preliminary action by pre-positioning the welding head relative to the battery before welding begins. The welding head is initially positioned at a predetermined offset from the battery, and both move together during welding. This preliminary setup eliminates the need for repeated positioning cycles, maintaining precision while improving production efficiency through continuous motion
2Manufacturing precision
If mechanical positioning is performed before each welding cycle, then welding accuracy is ensured, but production speed deteriorates due to inability to weld and move simultaneously
Solution Approach 1:
The patent implements continuous useful action by eliminating idle positioning time between welding cycles. The battery feeding and welding head movement occur simultaneously and continuously throughout the welding process. The feeding mechanism drives the battery forward while the welding head tracks along, ensuring that the useful action of welding continues without interruption, thereby maintaining accuracy while increasing production speed
Solution Approach 2:
The patent introduces an intermediary feeding mechanism that acts as a mediator between the battery and welding head. This feeding mechanism synchronizes the movement of both components, allowing them to move together at matched speeds. The intermediary ensures that welding accuracy is maintained through coordinated motion while enabling continuous production flow, thus resolving the speed-accuracy contradiction
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 reduces takt time and improves production efficiency by allowing the battery to move concurrently with the welding operation, enhancing throughput on high-speed production lines.
Implementation Method 1
a laser welding device, the laser welding device including at least a laser unit and a galvanometer unit, and the galvanometer unit being configured to deflect a laser emitted by the laser unit
Implementation Method 2
the laser welds a welding part of the battery when the battery is rotated about the first axis and the second axis
Data Source
AI summary
A welding device includes a rotating assembly, a bearing mechanism provided on the rotating assembly and actuated by the rotating assembly to rotate about a first axis, thereby cycling through a welding zone, an unloading zone, and a loading zone; the bearing mechanism includes at least a fixing assembly, which is switchable between a first state and a second state, wherein the fixing assembly fixes a battery, and at least a part of the fixing assembly is rotatable about a second axis to actuate the battery to rotate about the second axis in the first state; wherein the fixing assembly releases the battery in the second state; a laser welding device including at least a laser unit and a galvanometer unit, and the galvanometer unit being configured to deflect a laser emitted by the laser unit.