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Zero-defect wELDing for e-mobility

Zero-defect wELDing for e-mobility


Zero-defect wELDing for e-mobility's financial review


Zero-defect wELDing for e-mobility information

With the laser welding to be utilized more and more for the assembly of EV batteries, the overall quality of joints for tabs and busbars has been improved. However, some issues are still there. In case of fiber lasers for example, the welding of dissimilar non-ferrous materials like copper and aluminum is characterized by quality inconsistency, difficulties to maintain keyhole mode ΟΝ, and high en...
With the laser welding to be utilized more and more for the assembly of EV batteries, the overall quality of joints for tabs and busbars has been improved. However, some issues are still there. In case of fiber lasers for example, the welding of dissimilar non-ferrous materials like copper and aluminum is characterized by quality inconsistency, difficulties to maintain keyhole mode ΟΝ, and high energy demands.Such difficulties, along with the ever-increasing B.E.V production and the rise of the quality standards have configured a situation per which the current monitoring and quality control practices, (like sample-based destructive testing or even advanced online approaches for laser welding in general), are not suitable 100% for the laser welding of Battery cells.Finally, strengthening the position of E.U. battery assemblers with new production tools will shift the supply chain and boost business creation aspects.With these facts to be the main motivational points, the ZELD-e project was conceptualized and proposed a novel solution for advanced monitoring and control of laser welding for battery Tab-to-Tab and Tab-to-Busbar joining.Designed around an IoT device, the envisioned system incorporates a non-invasive monitoring setup using an Infrared and an RGB camera, re-trainable AI-based quality assessment, and process control software modules, as well as data analytic tools and data archiving features that can be accessed via a web-based user interface. The monitoring and quality assessment functionalities of the system were scheduled to be developed during 2021 while the rest of the features during 2022.

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