Process monitoring of ultrasonic metal welding of battery tabs using external sensor data
Ultrasonic metal welding (USMW) is a common used manufacturing technology for cell, module or pack assembly of Lithium-ion battery systems of pouch type. Since every single joint can affect the efficiency and safety of the entire battery system, quality fluctuations of the joint are one of the great...
Main Authors: | , , , , , , |
---|---|
Format: | Article |
Language: | English |
Published: |
Elsevier
2020-03-01
|
Series: | Journal of Advanced Joining Processes |
Subjects: | |
Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330920300030 |
id |
doaj-fbbd85f5963e463098cf8b0b73299b20 |
---|---|
record_format |
Article |
spelling |
doaj-fbbd85f5963e463098cf8b0b73299b202020-12-31T04:44:30ZengElsevierJournal of Advanced Joining Processes2666-33092020-03-011100005Process monitoring of ultrasonic metal welding of battery tabs using external sensor dataI. Balz0E. Abi Raad1E. Rosenthal2R. Lohoff3A. Schiebahn4U. Reisgen5M. Vorländer6RWTH Aachen University, ISF – Welding and Joining Institute, Pontstr. 49, 52062 Aachen, Germany; Corresponding author.RWTH Aachen University, Institute of Technical Acoustics, Kopernikusstraße 5, 52074 Aachen, GermanyForschungszentrum Jülich, ZEA-1 – Central Institute of Engineering, Electronics and Analytics, 52425 Jülich, GermanyForschungszentrum Jülich, ZEA-1 – Central Institute of Engineering, Electronics and Analytics, 52425 Jülich, GermanyRWTH Aachen University, ISF – Welding and Joining Institute, Pontstr. 49, 52062 Aachen, GermanyRWTH Aachen University, ISF – Welding and Joining Institute, Pontstr. 49, 52062 Aachen, GermanyRWTH Aachen University, Institute of Technical Acoustics, Kopernikusstraße 5, 52074 Aachen, GermanyUltrasonic metal welding (USMW) is a common used manufacturing technology for cell, module or pack assembly of Lithium-ion battery systems of pouch type. Since every single joint can affect the efficiency and safety of the entire battery system, quality fluctuations of the joint are one of the greatest challenges. Despite its industrial spread in battery manufacturing, USMW has a large number of influencing variables that may affect the bond quality but cannot be detected 100% failsafe with existing monitoring methods.Therefore the aim of this paper is to investigate the oscillation behavior of the tools and the joining members during USMW under different manufacturing conditions by monitoring external sensor data of structure-borne sound.In this paper typical manufacturing conditions in battery tab welding such as rolling direction and amplitude are set in order to study their effects on joint quality and the corresponding sensor signals. Therefore two laser vibrometers record the tool vibrations of the anvil and horn during the process. Occasionally, high-speed image capturing is also used to investigate the mechanism of process influences by studying the in-situ oscillation behavior of horn, anvil and the workpieces during USMW process. The sensor data analysis is correlated to thermal measurements and to the results of T-peel tensile testing and microstructural characterization of the bond interface to understand the effects of process influences during the welding process and its resulting joint quality.Based on the results, new insights for enhancing the process monitoring of USMW in Lithium-ion battery manufacturing are provided from identified sensor signals, that are correlating with the joint quality respectively different manufacturing conditions.http://www.sciencedirect.com/science/article/pii/S2666330920300030Ultrasonic metal weldingBattery manufacturingProcess monitoringSensorQuality control |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
I. Balz E. Abi Raad E. Rosenthal R. Lohoff A. Schiebahn U. Reisgen M. Vorländer |
spellingShingle |
I. Balz E. Abi Raad E. Rosenthal R. Lohoff A. Schiebahn U. Reisgen M. Vorländer Process monitoring of ultrasonic metal welding of battery tabs using external sensor data Journal of Advanced Joining Processes Ultrasonic metal welding Battery manufacturing Process monitoring Sensor Quality control |
author_facet |
I. Balz E. Abi Raad E. Rosenthal R. Lohoff A. Schiebahn U. Reisgen M. Vorländer |
author_sort |
I. Balz |
title |
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
title_short |
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
title_full |
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
title_fullStr |
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
title_full_unstemmed |
Process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
title_sort |
process monitoring of ultrasonic metal welding of battery tabs using external sensor data |
publisher |
Elsevier |
series |
Journal of Advanced Joining Processes |
issn |
2666-3309 |
publishDate |
2020-03-01 |
description |
Ultrasonic metal welding (USMW) is a common used manufacturing technology for cell, module or pack assembly of Lithium-ion battery systems of pouch type. Since every single joint can affect the efficiency and safety of the entire battery system, quality fluctuations of the joint are one of the greatest challenges. Despite its industrial spread in battery manufacturing, USMW has a large number of influencing variables that may affect the bond quality but cannot be detected 100% failsafe with existing monitoring methods.Therefore the aim of this paper is to investigate the oscillation behavior of the tools and the joining members during USMW under different manufacturing conditions by monitoring external sensor data of structure-borne sound.In this paper typical manufacturing conditions in battery tab welding such as rolling direction and amplitude are set in order to study their effects on joint quality and the corresponding sensor signals. Therefore two laser vibrometers record the tool vibrations of the anvil and horn during the process. Occasionally, high-speed image capturing is also used to investigate the mechanism of process influences by studying the in-situ oscillation behavior of horn, anvil and the workpieces during USMW process. The sensor data analysis is correlated to thermal measurements and to the results of T-peel tensile testing and microstructural characterization of the bond interface to understand the effects of process influences during the welding process and its resulting joint quality.Based on the results, new insights for enhancing the process monitoring of USMW in Lithium-ion battery manufacturing are provided from identified sensor signals, that are correlating with the joint quality respectively different manufacturing conditions. |
topic |
Ultrasonic metal welding Battery manufacturing Process monitoring Sensor Quality control |
url |
http://www.sciencedirect.com/science/article/pii/S2666330920300030 |
work_keys_str_mv |
AT ibalz processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT eabiraad processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT erosenthal processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT rlohoff processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT aschiebahn processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT ureisgen processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata AT mvorlander processmonitoringofultrasonicmetalweldingofbatterytabsusingexternalsensordata |
_version_ |
1724364943540617216 |