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Different welding processes are used depending on the design and requirements of each battery pack or module. Joints are also made to join the internal anode and cathode foils of battery cells, with ultrasonic welding (UW) being the preferred method for pouch cells.
Other joining methods such as micro-tungsten-inert-gas welding (micro-TIG), micro-clinching, soldering, and magnetic-pulse welding exist and have been proposed for battery assembly applications, but they are not well established, and therefore their feasibility is still being evaluated, or they are not widely used in the industry.
This means that, on the one hand, there may be accessibility issues as the testing is performed on already assembled modules or packs, and on the other hand, key performance indicators for battery welding applications, such as electrical and fatigue performance of the joints, are not served.
The quality assurance for battery welding applications is still in its infancy. Commercial solutions exist, but dedicated solutions are based on end-of-line approaches, while online solutions tend to address the generic quality issues of a specific welding process.
Process optimisation is by far the most researched area of quality assurance for battery welding applications. Most of the studies have been carried out either as pure experimental investigations to find the process parameters that optimise one or more KPIs of a joint, suppress defects, or validate a process model.
A computer takes multiple infrared images and applies a processing algorithm to create a surface map and identify hotspots. The system can detect various defects such as cold welds, weld cracks, incomplete penetration, and weld spatter .
Making battery packs is a common pursuit in our community, involving spot-welding nickel strips to the terminals on individual cells. Many a pack has been made in this way, using reclaimed 18650 ce…
Li-ion battery pack with a PCM and visual inspection system. The easy-wrinkled- or deflected-induced shadow images of the thin tabs hinder accurate inspection of the laser
The invention provides a method and a system for realizing battery PACK welding quality detection based on Labview programming, wherein the method comprises the steps of …
Within the context of a battery pack production scenario, this study introduces a novel online data-driven approach for assessing the resistance and maximum tensile shear …
For a battery welding scenario, this methodology achieved near perfect classification performance of good versus bad welds (cold welds) in terms of both Type I (false alarm) and Type II (misdetection) errors.
The main objectives of the battery pack detection model are, on the one hand, to detect the battery pack type so that the corresponding welding strategy or welding job is loaded into the …
At the heart of every plug-in, hybrid, or pure electric vehicle (EV) is a power source: a rechargeable battery pack, based on lithium-ion (li-ion) technology. And, whatever …
The invention provides a method and a system for realizing battery PACK welding quality …
The main objectives of the battery pack detection model are, on the one hand, to detect the …
Equipped with IsoFit® headgear and a rechargeable battery, it is suited for arc welding and laser welding within the 1000-1100 nm range. Lightweight at 685 g, it provides durability and high …
Aiming at the welding quality of a power battery, a three-dimensional detection method based on the line laser sensor was proposed. Firstly, the depth data of the weld …
This paper presents quality testing of battery pack welds for different welding time parameters of an automatic resistance spot welding machine. Several quality testing …
The advantages of Laser Welding beam welding are mainly related to the low electrical contact resistance (ECR) and the 12th CIRP Conference on Photonic Technologies …
To investigate battery faults detection and improve safety measures, some …
The invention discloses a battery pack welding quality image detection method, which belongs to the field of batteries, wherein a segmentation threshold is adopted for carrying out...
applications in battery cell welding. In summary, in the following paper, weld quality of a …
For a battery welding scenario, this methodology achieved near perfect classification performance of good versus bad welds (cold welds) in terms of both Type I (false …
Solar cells, Li-polymer battery pack, chargeable via Micro-USB: Battery Life: 300 to 500 charging cycles: Sensors: Five sensors: Sensitivity: Continuously, new with "Super High" sensitivity: …
Aiming at the welding quality of a power battery, a three-dimensional detection …
An essential part of the battery pack is the cooling and heating system. Whether plate heat exchangers, pipes or punch press profiles, TRUMPF offers the suitable production system for every design and material. This creates the optimum …
These welding processes were recorded by the thermographic camera A325sc by Flir. The battery cells, the conductors and the background were prepared with black chalk …
This paper presents quality testing of battery pack welds for different welding …
To investigate battery faults detection and improve safety measures, some preliminary researchers work on welding defects. Xie et al. [29] developed an improved …
The variable of greatest influence when welding battery packs is the contact resistance between the cell and the connection tab. It is crucial to minimize this ... ongoing market growth, battery …
Li-ion battery pack with a PCM and visual inspection system. The easy-wrinkled- or deflected-induced shadow images of the thin tabs hinder accurate inspection of the laser
applications in battery cell welding. In summary, in the following paper, weld quality of a personal transport device battery pack will be investigated using a programmable spot welding …