In the rapidly evolving field of battery manufacturing, the optimization of laser welding processes plays a pivotal role in enhancing production efficiency and product reliability. This presentation will explore innovative techniques using beam-shaping based on Multi-Plane Light Conversion technology to improve laser welding for battery components, including busbars, hairpins, and cell contacts. We will first discuss strategies to enhance weld quality by reducing porosity and minimizing spatters, critical factors that impact the structural integrity and electrical performance of battery assemblies. The study will be supported by high speed camera imaging. Further, we will delve into methods to increase the robustness of these welding processes. This includes improving tolerance to gaps between components, defocusing, and contamination on surfaces, which are common challenges in high-volume production settings. Additionally, the presentation will cover approaches to reduce the scrap rate during manufacturing, thereby enhancing overall yield and reducing waste. The scrap rate analysis will be supported by analysis of the signals of the Laser Welding Monitor sensor. Lastly, we will explore how beam-shaping enables welding speed increase, as well as welding speed decrease and deeper penetration when necessary. By addressing these key areas, the proposed advancements aim to significantly boost the efficiency and quality of battery manufacturing.
Keywords
- Beam-Shaping
- E-Mobility
- Laser Welding