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VIDEO DOI: https://doi.org/10.48448/j8ke-dm34
PAPER DOI: https://doi.org/10.2351/7.0001216

technical paper

ICALEO 2023

October 18, 2023

Chicago, United States

Inline Failure Detection in Laser Beam Welding of Battery Cells: Acoustic and Spectral Emission Analysis for Quality Monitoring

keywords:

welding process monitoring

inline detection of weld defects

quality control based on acoustic and spectral emission analysis

welding of battery cells

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.

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