Welding Rod Temperature Sensing and Cooling for Uniform Battery Welding
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Solution Overview
Problem
Conventional welding apparatuses for secondary batteries lack temperature control and cooling mechanisms, leading to overheating and non-uniform current application, which can damage electrodes and separators, and hinder efficient welding processes.
Innovation Solution
A welding apparatus equipped with a temperature measuring jig to monitor the welding rod's temperature and a welding rod cooler with a curved cooling panel and blower to rapidly cool the welding rod, ensuring precise temperature control and uniform welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional welding apparatus is used without temperature control, then the welding process is simple and fast, but the welding rod becomes overheated and may damage the electrode or separator
Solution Approach 1:
The cooling mechanism is activated before the welding rod becomes overheated, based on predetermined temperature thresholds. The controller activates the cooler when the temperature sensor detects temperatures exceeding preset limits, preventing heat damage before it occurs while maintaining efficient welding speed
Solution Approach 2:
A temperature sensor continuously monitors the welding rod's temperature and provides real-time feedback to the controller. The controller adjusts the cooling mechanism's operation based on this feedback, dynamically balancing welding speed with temperature control to prevent electrode or separator damage
2Device complexity
If the upper welding rod is not provided with a temperature measuring mechanism, then the apparatus structure is simple, but resistance fluctuates when temperature changes making it difficult to apply uniform current
Solution Approach 1:
A temperature sensor is integrated into the upper welding rod to continuously monitor temperature changes. This temperature feedback is transmitted to the controller, which adjusts the current in real-time to compensate for temperature-induced resistance variations, ensuring uniform current application throughout the welding process
Solution Approach 2:
The patent replaces manual or mechanical current adjustment mechanisms with an automated electronic control system. The controller uses temperature sensor data to automatically modulate the current, substituting precise electronic control for simpler mechanical systems that cannot respond dynamically to temperature changes
3Productivity
If the equipment moves quickly and the welding rod has a small outer diameter, then the welding process is efficient, but it becomes difficult to measure the temperature of the upper welding rod
Solution Approach 1:
A temperature sensor is introduced as an intermediary element that directly contacts or approaches the upper welding rod to measure its temperature. This sensor acts as a mediator between the small-diameter, fast-moving welding rod and the measurement system, enabling accurate temperature detection despite the rod's small size and rapid movement
Solution Approach 2:
The patent replaces complex mechanical measurement systems with electronic temperature sensing. The electronic sensor can rapidly respond to temperature changes on the small-diameter welding rod during fast movement, providing accurate measurements without the mechanical complexity and response delays of traditional measurement devices
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
The solution effectively manages heat and maintains uniform temperature, reducing welding defects and improving efficiency by allowing for precise temperature adjustments and rapid cooling, enhancing the overall quality of the welding process.
Implementation Method 1
a temperature sensor positioned at an upper end of the main body
Implementation Method 2
a blower, the blower being configured to blow cold air flowing through the blower through at least one cooling hole
Data Source
AI summary
A welding apparatus includes a welding rod; a temperature measuring jig to measure a temperature of the welding rod; and a welding rod cooler to cool the welding rod.