Description

The mobility sector is considered as 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 is required. 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 in order 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.

Contributing Authors

  • Johannes Heilmeier
    F & K Delvotec Bondtechnik GmbH
  • Michael K. Kick
    Technical University of Munich, TUM School of Engineering and Design, Department of Mechanical Engineering, Institute for Machine Tools and Industrial Management (iwb)
  • Sophie Grabmann
    Technical University of Munich, TUM School of Engineering and Design, Department of Mechanical Engineering, Institute for Machine Tools and Industrial Management (iwb)
  • Tatek Muschol
    F & K Delvotec Bondtechnik GmbH
  • Franz Schlicht
    F & K Delvotec Bondtechnik GmbH
  • Felix von Hundelshausen
    F & K Delvotec Bondtechnik GmbH
  • Hans-Georg von Ribbeck
    F & K Delvotec Bondtechnik GmbH
  • Tony Weiss
    Technical University of Munich, TUM School of Engineering and Design, Department of Mechanical Engineering, Institute for Machine Tools and Industrial Management (iwb)
  • Michael F. Zaeh
    Technical University of Munich, TUM School of Engineering and Design, Department of Mechanical Engineering, Institute for Machine Tools and Industrial Management (iwb)
Johannes Heilmeier
F & K Delvotec Bondtechnik GmbH
Track: Laser in Battery Manufacturing
Session: Battery Processing and Lasers
Day of Week: Wednesday
Date/Time:
Location: Salon 8 & 9

Keywords

  • Inline Detection Of Weld Defects
  • Quality Control Based On Acoustic And Spectral Emission Analysis
  • Welding Of Battery Cells
  • Welding Process Monitoring