Terminal Post Welding via Automatic Coordinate Addressing
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Solution Overview
Problem
Existing battery manufacturing technologies face challenges with large program development amounts and low efficiency in cutting, pulling, and model changing due to the need for different programs for various battery modules.
Innovation Solution
A post welding method and system that automatically determines the addressing and welding coordinates of cell posts based on product data, allowing for automatic addressing and positioning, reducing the need for multiple programs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a worker manually holds the terminal body and terminal post during welding, then positioning can be adjusted, but labor intensity increases and welding position may deviate due to hand fatigue
Solution Approach 1:
A support table is introduced as an intermediary device between the worker and the terminal components. The support table provides a stable surface for placing the terminal body and terminal post, eliminating the need for manual holding while maintaining positioning flexibility. This resolves the contradiction by transferring the support function from human hands to a dedicated tool.
Solution Approach 2:
The support table is designed with self-adjustable positioning mechanisms that allow the terminal components to be automatically positioned without continuous manual intervention. The structure enables self-alignment through gravitational settling or simple mechanical adjustments, reducing the need for complex active control systems.
2Stability of the object's composition
If the terminal post is clamped too tightly before welding, then positioning is fixed, but the post cannot be adjusted if it falls out of position during welding
Solution Approach 1:
The clamping mechanism transitions from a static fixed state to a dynamic adjustable state. During positioning, the clamp allows movement; during welding, it provides stable fixation. This dynamic behavior resolves the contradiction by adapting the constraint level to the operational phase, enabling both adjustment and stability at different times.
Solution Approach 2:
The terminal post is pre-positioned and loosely clamped before welding begins, allowing for final adjustments. The clamping force is then increased immediately before or during the welding process to prevent movement. This preliminary positioning followed by secure fixation resolves the contradiction between early adjustability and welding stability.
3Strength
If welding current is increased to improve welding quality, then weld strength increases, but the terminal post material may be damaged
Solution Approach 1:
The welding process uses pulsed current rather than continuous current. The current is applied in periodic pulses with controlled amplitude and duration, allowing the material to dissipate heat between pulses. This prevents thermal accumulation that would cause material damage while still achieving sufficient weld strength through repeated energy input.
Solution Approach 2:
The welding parameters (current amplitude, pulse duration, duty cycle) are optimized to achieve the required weld strength without exceeding material damage thresholds. By carefully controlling these parameters, the process achieves high weld quality while preventing burn-through or material degradation in the thin terminal post.
4Device complexity
If welding is performed without a support table, then the process is simpler, but welding quality deteriorates due to position deviation from hand fatigue
Solution Approach 1:
A support table is introduced as a simple intermediary device that provides a stable surface for positioning the terminal body and post during welding. This basic mechanical support eliminates position deviation caused by hand fatigue without requiring complex automation or control systems, thus improving precision while maintaining process simplicity.
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 approach reduces program development requirements, allows for efficient cutting, pulling, and model changing, and enhances overall production efficiency by enabling automatic determination of welding coordinates based on product data.
Implementation Method 1
a welding electrode is applied to perform welding
Implementation Method 2
welding current is applied during welding, it is greatly reflected by the terminal post, so the terminal post absorbs a lot of welding current energy, which easily causes damage to the terminal post material due to the small size of the terminal post
Data Source
Figure 1~3
Figure 4~5
AI summary
Embodiments of the present disclosure disclose a post welding method and a post welding system. The post welding method includes: addressing, under a guidance based on product data of a product to be welded, at least one cell post in the product to be welded, to obtain an addressing coordinate set of the at least one cell post, where the product data represents a product structure of the product to be welded, and the addressing coordinate set of the at least one cell post represents a position of the at least one cell post in the product to be welded in a current environment; and determining a welding coordinate set of the at least one cell post based on the addressing coordinate set of the at least one cell post, to implement, based on the welding coordinate set of the at least one cell post, electrical connections between cells in the product to be welded. Therefore, the method and the system can be applied to different types of products, to implement automatic addressing before welding of different products and automatic positioning of a welding point.