Dynamic Clamping Will Enable New Methods of Weld Quality Measurement for High-Speed Battery Welding Applications

ALAW (Novi, MI), June 18 - Battery module interconnection is a critical task in the manufacturing of batteries, particularly for electric vehicles (EVs), where high-quality welds are essential for safety and performance.

One of the main challenges in battery welding is fixturing, which directly influences weld quality. A key task is closing the gap between the current collector and the battery tab, which can be done using either static or dynamic clamping approaches. While static clamping is typically faster, dynamic clamping is more versatile as it allows adjusting clamping positions based on real-time camera feedback of individual cell/busbar positions.

Recent innovations have shown the potential to combine the versatility of dynamic clamping with the speed typically associated with static designs. This approach uses multiple high-speed SCARA robots, which dynamically adjust the XYZ positions to compensate for assembly variations. This allows for faster processing without sacrificing flexibility. Moreover, this dynamic tooling opens the opportunity for high-resolution 2D imaging of the welds under uniform illumination.

This imaging, combined with AI-driven analysis, enables real-time evaluation of weld quality and defect detection. By capturing high-resolution images, along with temperature, plasma, and acoustic signals, this technology improves weld quality evaluation, which is crucial for meeting the ultra-high-quality standards required for EV batteries.

A recent DOE study investigated the use of shear strength data for weld qualification, comparing the effectiveness of high-resolution 2D images, temperature, plasma, and acoustic signals in classifying weld quality. The study’s promising results demonstrate that the combination of dynamic clamping, high-resolution imaging, and AI analysis can lead to 6s weld quality, a benchmark for near-perfect production.

This approach not only improves weld quality but also minimizes capital investment costs and floor space requirements, making it an attractive solution for battery manufacturers. The findings of this study showcase how dynamic clamping, coupled with AI-powered weld analysis, can significantly enhance battery manufacturing processes by improving precision, speed, and defect detection while reducing the need for complex fixtures.

Laserax will showcase this innovation using its latest battery laser welding solutions—designed to meet all production needs, from R&D to full-scale manufacturing—at the upcoming Battery Show USA (October 6-9, Detroit, MI).

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