Inline failure detection in laser beam welding of battery cells: Acoustic and spectral emission analysis for quality monitoring

IF 1.7 4区 工程技术 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY Journal of Laser Applications Pub Date : 2024-03-14 DOI:10.2351/7.0001216
Johannes Heilmeier, Michael K. Kick, Sophie Grabmann, Tatek Muschol, Franz Schlicht, Felix von Hundelshausen, Hans-Georg von Ribbeck, T. Weiss, M. F. Zaeh
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Abstract

The mobility sector is considered a major contributor to global greenhouse gas emissions and air pollution. As a result, many countries have initiated the transition from fossil fuel-powered to electrified powertrains. This transformation of the powertrain concept will lead to a rapid increase in the production of electric vehicles and, therefore, to a high demand for so-called traction batteries. As a production step of the traction batteries, a connection between the cell connector and the terminal of the battery cell has to be manufactured. For this purpose, laser beam welding is a reliable and efficient joining technique. In order to ensure continuous quality of the welding process during production and to detect defects in real time, reliable process monitoring is required. In this study, spectral and acoustic emissions during laser beam welding were recorded using a laser welding monitor and an optical microphone. For determining possible correlations between the signals and weld defects, various failure cases were generated by the systematic placement of disturbance elements. These elements included a contaminated surface, a gap between the cell connector and the battery cell, and a misalignment of the cell connector. Based on the recorded signals, statistical metrics were calculated. Finally, weld seams with and without defects were compared to assess the capability of both sensor systems for detecting the weld defects.
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电池单元激光束焊接中的在线故障检测:用于质量监控的声学和光谱发射分析
汽车行业被认为是造成全球温室气体排放和空气污染的主要因素。因此,许多国家已开始从化石燃料动力系统向电气化动力系统过渡。动力总成概念的转变将导致电动汽车产量的快速增长,因此对所谓的牵引电池的需求也将随之增加。作为牵引电池的一个生产步骤,必须在电池连接器和电池单元端子之间建立连接。为此,激光束焊接是一种可靠而高效的连接技术。为了确保生产过程中焊接工艺的持续质量并实时检测缺陷,需要可靠的工艺监控。在这项研究中,使用激光焊接监控器和光学麦克风记录了激光束焊接过程中的光谱和声发射。为了确定信号与焊接缺陷之间可能存在的关联,通过系统性地放置干扰元素生成了各种故障案例。这些元素包括受污染的表面、电池连接器和电池单元之间的间隙以及电池连接器的错位。根据记录的信号计算出统计指标。最后,对有缺陷和无缺陷的焊缝进行了比较,以评估两种传感器系统检测焊缝缺陷的能力。
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来源期刊
CiteScore
3.60
自引率
9.50%
发文量
125
审稿时长
>12 weeks
期刊介绍: The Journal of Laser Applications (JLA) is the scientific platform of the Laser Institute of America (LIA) and is published in cooperation with AIP Publishing. The high-quality articles cover a broad range from fundamental and applied research and development to industrial applications. Therefore, JLA is a reflection of the state-of-R&D in photonic production, sensing and measurement as well as Laser safety. The following international and well known first-class scientists serve as allocated Editors in 9 new categories: High Precision Materials Processing with Ultrafast Lasers Laser Additive Manufacturing High Power Materials Processing with High Brightness Lasers Emerging Applications of Laser Technologies in High-performance/Multi-function Materials and Structures Surface Modification Lasers in Nanomanufacturing / Nanophotonics & Thin Film Technology Spectroscopy / Imaging / Diagnostics / Measurements Laser Systems and Markets Medical Applications & Safety Thermal Transportation Nanomaterials and Nanoprocessing Laser applications in Microelectronics.
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