Process monitoring of ultrasonic metal welding of battery tabs using external sensor data
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data
复制标题
使用外部传感器数据对电池极耳超声波金属焊接进行过程监控
DOI：
10.1016/j.jajp.2020.100005
复制
发表时间：
2020
影响因子：
4.1
通讯作者：
Vorländer
中科院分区：
文献类型：
--
作者：
Abi Raad;Rosenthal;Lohoff;Schiebahn;Reisgen;Vorländer
超声波金属焊接(USMW)是袋式锂离子电池系统电池、组件或组件的常用制造技术。由于每一个单独的接头都会影响整个电池系统的效率和安全，因此接头的质量波动是最大的挑战之一。尽管USMW在电池制造中广泛应用，但USMW存在大量可能影响焊接质量的影响变量，但现有的监测方法无法100%检测到这些变量的失效。因此，本文通过监测结构声的外部传感器数据，研究不同制造条件下USMW过程中刀具和连接构件的振动行为，并设置电池凸片焊接的典型制造条件，如轧制方向和振幅，研究它们对接头质量和相应传感器信号的影响。因此，两台激光测振仪记录了工具在加工过程中的振动情况。有时，还可以通过高速图像采集来研究USMW过程中喇叭、砧座和工件的原位振荡行为，以探讨工艺影响的机理。传感器数据分析与热测量、T-Peel拉伸测试和焊接界面微观结构表征结果相关联，以了解焊接过程中工艺影响的影响以及由此产生的接头质量。基于这些结果，从识别的传感器信号中为加强锂离子电池制造中USMW工艺监控提供了新的见解，这些传感器信号与不同制造条件下的接头质量相关联。
Ultrasonic metal welding (USMW) is a common used manufacturing technology for cell, module or pack assembly of Lithium-ion battery systems of pouch type. Since every single joint can affect the efficiency and safety of the entire battery system, quality fluctuations of the joint are one of the greatest challenges. Despite its industrial spread in battery manufacturing, USMW has a large number of influencing variables that may affect the bond quality but cannot be detected 100% failsafe with existing monitoring methods.Therefore the aim of this paper is to investigate the oscillation behavior of the tools and the joining members during USMW under different manufacturing conditions by monitoring external sensor data of structure-borne sound.In this paper typical manufacturing conditions in battery tab welding such as rolling direction and amplitude are set in order to study their effects on joint quality and the corresponding sensor signals. Therefore two laser vibrometers record the tool vibrations of the anvil and horn during the process. Occasionally, high-speed image capturing is also used to investigate the mechanism of process influences by studying the in-situ oscillation behavior of horn, anvil and the workpieces during USMW process. The sensor data analysis is correlated to thermal measurements and to the results of T-peel tensile testing and microstructural characterization of the bond interface to understand the effects of process influences during the welding process and its resulting joint quality.Based on the results, new insights for enhancing the process monitoring of USMW in Lithium-ion battery manufacturing are provided from identified sensor signals, that are correlating with the joint quality respectively different manufacturing conditions.