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WO2024046435A1 - 电池焊接系统及电池焊接方法 - Google Patents

电池焊接系统及电池焊接方法 Download PDF

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Publication number
WO2024046435A1
WO2024046435A1 PCT/CN2023/116263 CN2023116263W WO2024046435A1 WO 2024046435 A1 WO2024046435 A1 WO 2024046435A1 CN 2023116263 W CN2023116263 W CN 2023116263W WO 2024046435 A1 WO2024046435 A1 WO 2024046435A1
Authority
WO
WIPO (PCT)
Prior art keywords
welding
top cover
battery
image
preset
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2023/116263
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English (en)
French (fr)
Inventor
吴兆仁
刘�东
丁辉
高健
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wuxi Lead Intelligent Equipment Co Ltd
Original Assignee
Wuxi Lead Intelligent Equipment Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wuxi Lead Intelligent Equipment Co Ltd filed Critical Wuxi Lead Intelligent Equipment Co Ltd
Publication of WO2024046435A1 publication Critical patent/WO2024046435A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/04—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
    • B23K37/0426—Fixtures for other work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0247—Driving means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0252—Steering means
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/60—Analysis of geometric attributes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/147—Lids or covers
    • H01M50/166—Lids or covers characterised by the methods of assembling casings with lids
    • H01M50/169—Lids or covers characterised by the methods of assembling casings with lids by welding, brazing or soldering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/10—Image acquisition modality
    • G06T2207/10028—Range image; Depth image; 3D point clouds
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection

Definitions

  • the present disclosure relates to the technical field of battery manufacturing, and in particular to a battery welding system and a battery welding method.
  • the top cover welding machine welds the top cover and casing of the battery, it uses key points to confirm and determine the welding trajectory.
  • the present disclosure is intended to alleviate or solve, at least to some extent, at least one of the above-mentioned problems.
  • the present disclosure proposes a battery welding system for welding the top cover and casing of the battery, including: a welding head, a profiler and a servo motion module; wherein, the profiler is used for Obtain the outline image of the step between the top cover and the casing, and obtain the parameter measurement value of the step based on the outline image; wherein, after the battery core is inserted into the case, the The height and width between the top cover and the housing form the step; a servo movement module, the profiler and the welding head are provided on the servo movement module and are used to measure the top cover according to the The preset welding trajectory of the cover and the housing and the parameter measurement value control the welding head to weld the top cover and the housing.
  • the present disclosure proposes a battery welding method for the above-mentioned battery welding system.
  • the method includes: obtaining an outline image of the step between the top cover and the housing; based on the The outline image of the step is obtained to obtain the parameter measurement value of the step; the servo motion module moves according to the preset welding trajectory and adjusts the welding head to the preset welding position based on the parameter measurement value of the step to achieve alignment. Welding of the top cover and the casing.
  • the battery welding system proposed in this disclosure can ensure that the welding of the top cover and the case is always based on actual conditions by detecting changes in step width in real time and adjusting the position of the welding focus relative to the top cover boundary and the case boundary.
  • the welding path is carried out to achieve better welding quality.
  • Figure 1a shows a schematic diagram of the ideal welding trajectory of the battery
  • Figure 1b shows a schematic diagram of the actual welding trajectory of the battery
  • Figure 2 shows a schematic diagram of a battery structure according to an embodiment of the present disclosure
  • Figure 3 shows a schematic top view of the battery in Figure 2;
  • Figure 4 shows a schematic structural diagram of a battery welding system according to an embodiment of the present disclosure
  • Figure 5 shows a schematic diagram of battery welding results according to one embodiment of the present disclosure
  • Figure 6 shows a schematic flowchart of contour image detection according to an embodiment of the present disclosure
  • Figure 7 shows a schematic diagram of battery welding results according to one embodiment of the present disclosure
  • Figure 8 shows a schematic flow chart of step measurement parameter detection according to one embodiment of the present disclosure
  • Figure 9 shows a schematic flow chart of welding quality inspection according to one embodiment of the present disclosure.
  • user information including but not limited to user equipment information, user personal information, etc.
  • data including but not limited to data for display, data for analysis, etc.
  • the actual preset welding track is compared with the ideal preset welding track due to the uneven gap between the casing and the top cover and the deformation of the casing. Under the influence of factors such as uneven pressure of tooling fixtures, the welding track is deformed.
  • the height and width of the top cover and the case form steps.
  • the top cover closes the port where the power supply core enters the case and covers the battery core.
  • the height of the top cover in the case is lower than the height of the case. This height is a step. height; the outer circumferential edge of the top cover and the inner circumferential edge of the shell have a certain width, which is the step width (also called a gap, which is a reserved welding gap used to form a molten pool after welding).
  • the welding system includes: a welding head 10, a profiler 20, a servo motion module 30, a welding feed motor 40, and a gantry support base 50 , gantry bracket 60 and industrial computer 70.
  • the welding head 10 and the profiler 20 are provided in the servo motion module 30 .
  • the welding head 10 can be a laser welding head, which can keep the defocus amount stable during the movement and weld the top cover and the shell;
  • the profiler 20 can be a 3D profiler, which can collect the top cover in real time during the movement.
  • the servo motion module 30 and the welding feed motor 40 are in matching positions.
  • the servo motion module 30 may be located above the welding feed motor 40 .
  • the servo motion module 30 can follow the edge of the top cover and the edge of the casing (ie: the horizontal direction of the top cover and the casing). Preset welding trajectory movement confirmed by a certain number of key points in the cross-sectional shape).
  • the servo motion module 30 is installed on the gantry bracket base 50 , and the gantry bracket base 50 is installed on the gantry bracket 60 . Thus, the servo motion module 30 , the profiler 20 and the welding head 10 are supported.
  • the parameter measurement values of the steps can be obtained based on the profile image; the welding quality of the molten pool can be obtained based on the molten pool image.
  • the profiler 20 includes a transmitting component (not labeled in the figure) and a receiving component (not labeled in the figure).
  • the transmitting component emits a transmitting beam 21 to the top cover and the casing
  • the receiving component receives the reflected beam 22 of the transmitting beam on the top cover and the casing respectively, thus obtaining a profile image of the step, and obtaining parameter measurements of the step based on the profile image.
  • the profiler 20 is also used to obtain an image of the molten pool after welding the top cover and the shell, so as to obtain a molten pool image of the molten pool, and obtain the welding quality based on the molten pool image.
  • the industrial computer 70 is communicated with the welding head 10, the profiler 20, the servo motion module 30, and the welding feed motor 40 respectively.
  • the communication connection is realized by using an Ethernet network.
  • the industrial computer 70 calculates the parameter measurement value of the step based on the step profile image sent by the profiler 20, and controls the servo motion module 30 to adjust the welding focus of the welding head 10 at the preset welding position during the movement according to the preset welding trajectory to control
  • the welding head 10 welds the top cover and the shell; simultaneously, the profiler 20 collects real-time images of the welded molten pool, and the industrial computer 70 judges the welding quality based on the image of the molten pool sent by the profiler 20 .
  • the industrial computer 70 controls the welding feed motor 40 to carry the next battery top cover and casing to be welded to the preset position.
  • the parameter measurement value of the step includes the coordinates of the center point of the step. While the servo motion module 30 moves according to the preset welding trajectory, the industrial computer 70 adjusts the welding focus of the welding head 10 to the position of the coordinates of the center point of the step. Since the coordinates of the center point are detected in real time, when the welding gap between the top cover and the shell changes (that is, the width and/or width of the step changes), it can always be ensured that the welding focus of the welding head 10 is at the time when the change occurs. The coordinate position of the step center point ensures the stability of the defocus amount and the fit between the actual welding trajectory and the actual step path.
  • the profiler 20 is also used to collect the grayscale image of the completed welding pool in real time.
  • the profiler 20 can be arranged at an angle with the welding head 10, and the welding focus axis of the welding head 10 forms an acute angle with the emitted beam of the profiler 20. state, so that the acquisition area of the profilometer 20 includes the step longitudinal section, so that the grayscale image of the molten pool collected by the profilometer 20 includes the image content of the molten pool in the step height direction.
  • the profiler 20 sends the grayscale image of the molten pool to the industrial computer 70, and the industrial computer 70 detects the welding quality of the molten pool based on the grayscale image of the molten pool.
  • embodiments of the present disclosure also provide a battery welding method. As shown in Figure 5, the method includes the following steps:
  • Step 510 Obtain an outline image of the step between the top cover and the housing.
  • Step 520 Obtain the parameter measurement value of the step based on the outline image of the step. Combined with Figure 3, it can be seen that the parameter measurement values of the steps include the width of the steps (ie, the welding gap), height and center point coordinates.
  • Step 530 During the movement of the servo motion module 30 according to the preset welding trajectory, adjust the welding head 10 to the preset welding position based on the parameter measurement value of the step to achieve Welding of the top cover and the casing.
  • step 510 includes:
  • Step 610 Obtain the point cloud image of the top cover and the point cloud image of the housing.
  • Step 620 Reconstruct the point cloud image of the top cover and the point cloud image of the housing to obtain an outline image of the step.
  • the light beam emitted by the transmitting component is irradiated to the top cover and the casing respectively, and the reflection component receives the top cover point cloud image reflected by the top cover and the casing point cloud image reflected by the casing, and compares the top cover point cloud image and the casing.
  • the point cloud image is reconstructed to obtain the top cover contour image, the shell contour image and the contour image of the steps between them.
  • step 520 includes:
  • Step 810 Obtain the width and height of the step based on the first reflected beam, the second emitted beam and the profile image of the step;
  • Step 820 Based on the width and the height, obtain the center point coordinates of the step.
  • the top cover when the top cover is embedded in the casing, the top cover is low and the casing is high.
  • the first emitting beam and the second emitting beam are on two planes corresponding to the top cover and the casing respectively.
  • a misaligned parallel line is formed on the step, and the width and height of the step can be obtained based on the misaligned parallel line.
  • the center point based on the width is the transverse center coordinate of the center point
  • the center point based on the height is the longitudinal center coordinate of the center point. From this, the center point coordinates of the step are obtained.
  • step 530 includes:
  • Step 910 Based on the preset welding trajectory and the center point coordinates, during the movement of the servo motion module 30 according to the preset welding trajectory, determine the preset welding position of the welding head 10, wherein, The preset welding track is obtained based on the edge of the top cover and the edge of the housing;
  • Step 920 Control the welding head 10 to weld the top cover and the shell and form a molten pool in the step.
  • the battery welding system detects the welding quality in real time while welding.
  • the method also includes the following steps:
  • Step 540 During the movement of the servo motion module 30 according to the preset welding trajectory, obtain the grayscale image of the molten pool of the top cover and the shell by the profiler 20;
  • Step 550 Confirm the welding quality of the step and the shell based on the grayscale image of the molten pool.
  • the profiler 20 collects the molten pool image in real time during the welding process, and the pre-trained defect detection neural network in the industrial computer 70 identifies the grayscale image of the molten pool to determine the welding quality. And record the welding quality evaluation results of each frame into the database.
  • the current method of testing the welding quality of the battery top cover and casing uses visual inspection after the welding is completed and cutting samples to sample and measure the welding penetration.
  • This method has the following shortcomings: (1) After the welding is completed Visual inspection only collects images of the surface topography of the weld, and performs defect detection through image processing. It cannot observe the penetration depth and internal defects of the weld, and is easily affected by welding slag, welding ash, etc., leading to a high degree of misjudgment. rate; (2) Sampling the products after welding is completed, cutting the welds, observing the penetration data of the end face to detect the welding quality, and estimating the welding quality of large batches of product welds through a smaller number of sample data, there is randomness sex and subjectivity. Based on the above method, the quality of the molten pool can be detected in real time, and the quality results are guaranteed to include penetration depth and internal defects, achieving better detection results.
  • a computer-readable storage medium is also provided, which when instructions in the storage medium are executed by the processor of the industrial computer 70 enables the electronic device to perform the method in the embodiment of the present disclosure.
  • Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory.
  • Volatile memory may include random access memory (RAM) or external cache memory.
  • RAM is available in many forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous chain Synchlink DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.
  • SRAM static RAM
  • DRAM dynamic RAM
  • SDRAM synchronous DRAM
  • DDRSDRAM double data rate SDRAM
  • ESDRAM enhanced SDRAM
  • SLDRAM synchronous chain Synchlink DRAM
  • Rambus direct RAM
  • DRAM direct memory bus dynamic RAM
  • RDRAM memory bus dynamic RAM

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Abstract

一种电池焊接系统，包括：焊接头(10)、轮廓仪(20)和伺服运动模组(30)；其中，轮廓仪用于获取顶盖和壳体之间台阶的轮廓图像，基于轮廓图像获得台阶的参数测量值；轮廓仪和焊接头设置于伺服运动模组，并用于根据对顶盖和壳体的预设焊接轨迹以及参数测量值控制焊接头对顶盖和壳体进行焊接。该电池焊接系统通过实时检测台阶宽度的变化和调整焊接焦点的位置相对于顶盖边界、壳体边界的相对固定，能够确保对顶盖和壳体的焊接始终基于实际焊接轨迹进行，实现较佳的焊接质量。还涉及一种电池的焊接方法。

Description

电池焊接系统及电池焊接方法
本公开要求于2022年9月02日提交中国专利局，申请号为202211072610.3，申请名称为“电池焊接系统及电池焊接方法”的中国专利申请的优先权，其全部内容通过引用结合在本公开中。
技术领域
本公开涉及电池制造技术领域，尤其涉及电池焊接系统及电池焊接方法。
背景技术
相关技术中，顶盖焊接机在对电池的顶盖和壳体焊接时，采用关键点位方式确认确定焊接轨迹。
以方形电池为例，如图1a所述，其是基于顶盖和壳体的壳体截面之间的缝隙为标准矩形(顶盖和壳体的四个顶点为关键点位)的假设为前提，确认的理想焊接轨迹；如图1b所示，其是焊接轨迹由于受到壳体和顶盖之间缝隙不均匀、壳体变形、工装夹具压力不均匀等因素的影响下，焊接轨迹为波浪形的焊接轨迹。
在焊接过程中，由于焊接轨迹的变形，会导致焊接时离焦量不均匀、焊接熔深一致性不足、焊穿、气泡、飞溅等焊接缺陷；如何实时调整顶盖焊接机的焊接轨迹，是保证焊接亟需解决的问题。
发明内容
本公开旨在至少一定程度上缓解或解决上述提及问题中的至少一个。
在本公开的一个方面，本公开提出了一种电池焊接系统，用于对电池的顶盖和壳体的焊接，包括：焊接头、轮廓仪和伺服运动模组；其中，轮廓仪，用于获取所述顶盖和所述壳体之间台阶的轮廓图像，基于所述轮廓图像获得所述台阶的参数测量值；其中，所述电池的电芯在入壳后，所述 顶盖和所述壳体彼此之间具有的高度和宽度形成所述台阶；伺服运动模组，所述轮廓仪和所述焊接头设置于所述伺服运动模组，并用于根据对所述顶盖和所述壳体的预设焊接轨迹以及所述参数测量值控制所述焊接头对所述顶盖和所述壳体进行焊接。
在本公开的另一个方面，本公开提出了一种电池焊接方法，用于上述的电池焊接系统，所述方法包括：获取所述顶盖和所述壳体之间台阶的轮廓图像；基于所述台阶的轮廓图像，得到所述台阶的参数测量值；所述伺服运动模组按照预设焊接轨迹运动并基于所述台阶的参数测量值调整所述焊接头处于预设焊接位置，以实现对所述顶盖和所述壳体的焊接。
由此，本公开提出的电池焊接系统，通过实时检测台阶宽度的变化和调整焊接焦点的位置相对于顶盖边界、壳体边界的相对固定，能够确保对顶盖和壳体的焊接始终基于实际焊接轨迹进行，实现较佳的焊接质量。
附图说明
本公开的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1a显示了电池的理想焊接轨迹的示意图；
图1b显示了电池的实际焊接轨迹的示意图；
图2显示了根据本公开一个实施例的一种电池结构的示意图；
图3显示了图2中电池的俯视示意图；
图4显示了根据本公开一个实施例的电池焊接系统的结构示意图；
图5显示了根据本公开一个实施例的电池焊接结果的示意图；
图6显示了根据本公开一个实施例的轮廓图像检测的流程示意图；
图7显示了根据本公开一个实施例的电池焊接结果的示意图；
图8显示了根据本公开一个实施例的台阶测量参数检测流程示意图；
图9显示了根据本公开一个实施例的焊接质量检测流程示意图。
附图标记说明：
焊接头10；
轮廓仪20；发射光束21；反射光束22；
伺服运动模组30；焊接进给电机40；龙门支架底座50；龙门支架60；
工控机70。
具体实施方式
为了使本领域普通人员更好地理解本公开的技术方案，下面将结合附图，对本公开实施例中的技术方案进行清楚、完整地描述。
需要说明的是，本公开的说明书和权利要求书及上述附图中的术语“第一”、“第二”等是用于区别类似的对象，而不必用于描述特定的顺序或先后次序。应该理解这样使用的数据在适当情况下可以互换，以便这里描述的本公开的实施例能够以除了在这里图示或描述的那些以外的顺序实施。以下示例性实施例中所描述的实施方式并不代表与本公开相一致的所有实施方式。相反，它们仅是与如所附权利要求书中所详述的、本公开的一些方面相一致的装置和方法的例子。
需要说明的是，本公开所涉及的用户信息(包括但不限于用户设备信息、用户个人信息等)和数据(包括但不限于用于展示的数据、分析的数据等)，均为经用户授权或者经过各方充分授权的信息和数据。
在基于关键点标定的电池顶盖和壳体之间的焊接轨迹，实际的预设焊接轨迹和理想的预设焊接轨迹相比，由于受到壳体和顶盖之间缝隙不均匀、壳体变形、工装夹具压力不均匀等因素的影响下，导致焊接轨迹为焊接轨迹变形。
如图2和图3所示，电池的电芯(图未绘示)入壳后，顶盖和壳体彼此之间具有的高度和宽度形成台阶。以方壳电池为例，电芯在入壳后，顶盖封闭壳体的供电芯入壳的端口并覆盖于电芯，顶盖在壳体内的高度低于壳体的高度，该高度为台阶的高度；顶盖的外周向边缘与壳体的内周向边缘具有一定的宽度，该宽度即为台阶宽度(也称为缝隙，为预留焊接缝隙，用于形成焊接后的熔池)。在电池顶盖和壳体的焊接过程中，需要实时检测台阶宽度的变化，保证焊接焦点始终位于同一预设焊接位置对顶盖和壳体进行焊接。例如，使焊接的焦点始终位于宽度的中心位置等。通过实时 检测台阶宽度的变化和调整焊接焦点的位置相对于顶盖边界、壳体边界的相对固定，能够确保对顶盖和壳体的焊接始终基于实际焊接轨迹进行，实现较佳的焊接质量。
基于此，本公开实施例提供了一种电池焊接系统，如图4所示，该焊接系统包括：焊接头10、轮廓仪20、伺服运动模组30、焊接进给电机40、龙门支架底座50、龙门支架60和工控机70。
焊接头10和轮廓仪20设置于伺服运动模组30。其中，焊接头10可以为激光焊接头，其可在运动过程保持离焦量稳定并对顶盖和壳体进行焊接；轮廓仪20可以为3D轮廓仪，其可在运动过程中实时采集顶盖和壳体焊接前的台阶轮廓图像、以及顶盖和壳体焊接后熔池图像；伺服运动模组30如可沿轴向、横向运动，其可带动焊接头10和轮廓仪20沿顶盖和壳体之间预设的焊接轨迹运动，并在运动过程中基于参数测量值控制焊接头10的焊接焦点保持在预设的焊接位置。
在电池焊接系统中，伺服运动模组30和焊接进给电机40处于相匹配的位置。例如，承载电池顶盖和壳体的焊接给进电机40位于下方时，伺服运动模组30可位于焊接给进电机40的上方。当焊接给进电机40将需要焊接的电池顶盖和壳体承载到预设位置时，伺服运动模组30可以按照该顶盖的边缘和壳体的边缘(即：顶盖和壳体的横截面形状)中一定数量的关键点位确认的预设焊接轨迹运动。
伺服运动模组30安装于龙门支架底座50，龙门支架底座50安装于龙门支架60。由此，实现对伺服运动模组30、轮廓仪20和焊接头10支撑。
需要进一步说明的是，基于轮廓图像可获得台阶的参数测量值；基于熔池图像可获得熔池的焊接质量。
具体而言，轮廓仪20包括发射组件(图未标注)和接收组件(图未标注)。发射组件向顶盖和壳体发射出发射光束21，接收组件接收发射光束分别在顶盖和壳体的反射光束22，这样就获得台阶的轮廓图像，基于轮廓图像获取所述台阶的参数测量值。此外，轮廓仪20还用于获取对顶盖和壳体焊接后熔池图像，这样就获得熔池的熔池图像，基于熔池图像获取焊接质量。
工控机70与焊接头10、轮廓仪20、伺服运动模组30、焊接进给电机40分别通信连接，例如，采用以太网络的方式实现通信连接。工控机70基于轮廓仪20发送台阶轮廓图像计算台阶的参数测量值，并控制伺服运动模组30在按照预设焊接轨迹运动的过程中调整焊接头10的焊接焦点位于预设焊接位置，以控制焊接头10对顶盖和壳体进行焊接；同步的，轮廓仪20对焊接完成的熔池进行实时图像采集，工控机70基于轮廓仪20发送熔池图像判断焊接质量。在每一个电池焊接完成后，工控机70控制焊接进给电机40将下一个需要焊接的电池顶盖和壳体承载到预设位置。
需要进一步说明的是，台阶的参数测量值包括台阶的中心点坐标。伺服运动模组30在按照预设焊接轨迹运动的过程中，工控机70调整焊接头10的焊接焦点位于台阶的中心点坐标的位置。由于，该中心点坐标是实时检测的，在顶盖和壳体之间焊接缝隙(即台阶的宽度和/或宽度发生改变)发生改变时，能够始终保证焊接头10的焊接焦点位于发生改变时的台阶中心点的坐标位置，从而保证离焦量稳定以及实际焊接轨迹与实际台阶路径的贴合。
此外，轮廓仪20还用于实时采集完成焊接熔池的灰度图像，轮廓仪20可以与焊接头10呈倾斜设置，焊接头10的焊接焦点轴向与轮廓仪20的发射光束之间呈锐角状态，使得轮廓仪20的采集区域包括台阶纵向截面，这样轮廓仪20采集的熔池灰度图像包括熔池在台阶高度方向的图像内容。轮廓仪20将熔池的灰度图像发送至工控机70，工控机70基于熔池的灰度图像对熔池的焊接质量进行检测。
基于上述电池焊接系统，本公开实施例还提供了一种电池焊接方法，如图5所示，该方法包括以下步骤：
步骤510：获取所述顶盖和所述壳体之间台阶的轮廓图像。
步骤520：基于所述台阶的轮廓图像，得到所述台阶的参数测量值。结合图3可知，台阶的参数测量值包括台阶的宽度(即焊接缝隙)、高度和中心点坐标。
步骤530：在所述伺服运动模组30按照预设焊接轨迹的运动的过程中，基于所述台阶的参数测量值调整所述焊接头10处于预设焊接位置，以实现 对所述顶盖和所述壳体的焊接。
如图6和图7所示，上述步骤510，包括：
步骤610：获取所述顶盖的点云图像和所述壳体的点云图像。
步骤620：对所述顶盖的点云图像和所述壳体的点云图像进行重建，得到所述台阶的轮廓图像。
具体的，发射组件发射的光束分别照射于到顶盖和壳体，反射组件接收顶盖反射的顶盖点云图像和壳体反射的壳体点云图像，对顶盖殿点云图像和壳体点云图像进行重建，分别得到顶盖轮廓图像、壳体轮廓图像和它们之间台阶的轮廓图像。
如图8所示，上述步骤520，包括：
步骤810：基于所述第一反射光束、所述第二发射光束和所述台阶的轮廓图像，得到所述台阶的宽度和高度；
步骤820：基于所述宽度和所述高度，得到所述台阶的中心点坐标。
具体的，结合图7所示，例如在顶盖嵌入壳体的情况下，此时顶盖低、壳体高，第一发射光束和第二发射光束在顶盖和壳体分别对应的两个平面上形成错位平行线，基于该错位平行线即可得到台阶的宽度和高度。同理，基于所述宽度的中线点即得到中心点的横向中心坐标，基于高度的中心点即得到中心点的纵向中心坐标，由此，得到台阶的中心点坐标。
如图9所示，上述步骤530，包括：
步骤910：基于所述预设焊接轨迹和所述中心点坐标，在所述伺服运动模组30按照预设焊接轨迹的运动的过程中，确定所述焊接头10的预设焊接位置，其中，所述预设焊接轨迹基于所述顶盖的边缘和所述壳体的边缘得到；
步骤920：控制所述焊接头10，对所述顶盖和所述壳体进行焊接并在所述台阶内形成熔池。
承图5所述，电池焊接系统在焊接的同时，实时对焊接质量进行检测。该方法还包括以下步骤：
步骤540：在所述伺服运动模组30按照预设焊接轨迹的运动的过程中，获取所述轮廓仪20对所述顶盖和所述壳体的熔池的灰度图像；
步骤550：基于所述熔池的灰度图像，确认对所述台阶和所述壳体的焊接质量。
从焊接开始至焊接结束的过程中，轮廓仪20实时采集焊接过程中的熔池图像，并由工控机70中的预训练的缺陷检测神经网络对熔池灰度图像进行识别，确定焊接质量，并将每帧的焊接质量评估结果记录至数据库中。
目前的对电池顶盖和壳体焊接质量的检测方法中，采用的是焊接完成后进行视觉检测以及切割样品进行抽样测量焊接熔深的方式进行，该方式存在如下缺点：(1)焊接完成后视觉检测只对焊缝表面的形貌进行图像采集，通过图像处理来进行缺陷检测，无法观察到焊缝的熔深和内部缺陷，并且容易受到焊渣、焊灰等影响，导致较高误判率；(2)对焊接完成后产品进行抽样，并切割焊缝，观察端面的熔深数据的方式检测焊接质量，通过较小数量的样本数据估计大批量的产品焊缝的焊接质量，存在随机性和主观性。基于上述方式，能够实时检测熔池的质量，并保证其质量结果包括熔深和内部缺陷的内容，达到更好的检测效果。
在示例性实施例中，还提供了一种计算机可读存储介质，当该存储介质中的指令由工控机70的处理器执行时，使得电子设备能够执行本公开实施例中的方法。
本领域普通技术人员可以理解实现上述实施例方法中的全部或部分流程，是可以通过计算机程序来指令相关的硬件来完成，该计算机程序可存储于一非易失性计算机可读取存储介质中，该计算机程序在执行时，可包括如上述各方法的实施例的流程。其中，本公开所提供的各实施例中所使用的对存储器、存储、数据库或其它介质的任何引用，均可包括非易失性和/或易失性存储器。非易失性存储器可包括只读存储器(ROM)、可编程ROM(PROM)、电可编程ROM(EPROM)、电可擦除可编程ROM(EEPROM)或闪存。易失性存储器可包括随机存取存储器(RAM)或者外部高速缓冲存储器。作为说明而非局限，RAM以多种形式可得，诸如静态RAM(SRAM)、动态RAM(DRAM)、同步DRAM(SDRAM)、双数据率SDRAM(DDRSDRAM)、增强型SDRAM(ESDRAM)、同步链路(Synchlink)DRAM(SLDRAM)、存储器总线(Rambus)直接RAM(RDRAM)、直接存储器总线动态RAM(DRDRAM)、以及存储器总线动态 RAM(RDRAM)等。
本领域技术人员在考虑说明书及实践这里公开的发明后，将容易想到本公开的其它实施方案。本公开旨在涵盖本公开的任何变型、用途或者适应性变化，这些变型、用途或者适应性变化遵循本公开的一般性原理并包括本公开未公开的本技术领域中的公知常识或惯用技术手段。说明书和实施例仅被视为示例性的，本公开的真正范围和精神由下面的权利要求指出。
应当理解的是，本公开并不局限于上面已经描述并在附图中示出的精确结构，并且可以在不脱离其范围进行各种修改和改变。本公开的范围仅由所附的权利要求来限制。

Claims (11)

  1. 一种电池焊接系统，用于对电池的顶盖和壳体的焊接，其特征在于，包括：
    焊接头(10)；
    轮廓仪(20)，用于获取所述顶盖和所述壳体之间台阶的轮廓图像，基于所述轮廓图像获得所述台阶的参数测量值；其中，所述电池的电芯在入壳后，所述顶盖和所述壳体彼此之间具有的高度和宽度形成所述台阶；
    伺服运动模组(30)，所述轮廓仪(20)和所述焊接头(10)设置于所述伺服运动模组(30)，并用于根据对所述顶盖和所述壳体的预设焊接轨迹以及所述参数测量值控制所述焊接头(10)对所述顶盖和所述壳体进行焊接。
  2. 根据权利要求1所述的电池焊接系统，其特征在于，所述轮廓仪(20)包括发射组件和接收组件，所述发射组件分别向所述顶盖和所述壳体的发射光束，所述接收组件接收所述顶盖和所述壳体的反射光束，根据所述反射光束得到所述轮廓图像，根据所述台阶的参数测量值获取所对所述台阶焊接的预设焊接位置；
    所述伺服运动模组(30)在沿所述预设焊接轨迹运动的过程中，控制所述焊接头(10)的焊接焦点位于所述预设焊接位置。
  3. 根据权利要求1或2所述的电池焊接系统，其特征在于，所述轮廓仪(20)采集区域包括所述台阶纵向截面；所述轮廓仪(20)还用于获取对所述顶盖和所述壳体焊接后熔池的图像，基于所述熔池图像获取焊接质量。
  4. 根据权利要求2或3所述的电池焊接系统，其特征在于，还包括：工控机(70)，所述工控机(70)基于所述轮廓仪(20)发送的所述台阶轮廓图像计算所述台阶的参数测量值，并控制所述伺服运动模组(30)在 按照预设焊接轨迹运动的过程中调整所述焊接头(10)的焊接焦点位于所述预设焊接位置，以控制所述焊接头(10)对所述顶盖和所述壳体进行焊接。
  5. 根据权利要求4所述的电池焊接系统，其特征在于，所述参数测量值包括所述台阶的中心点坐标，所述伺服运动模组(30)在按照预设焊接轨迹运动的过程中，调整所述焊接头(10)的焊接焦点位于所述台阶的中心点坐标的位置。
  6. 根据权利要求4或5所述的电池焊接系统，其特征在于，所述伺服运动模组(30)在按照预设焊接轨迹运动的过程中，所述轮廓仪(20)还用于实时采集完成焊接所述熔池的灰度图像，并将所述熔池的灰度图像发送至所述工控机(70)，所述工控机(70)基于所述熔池的灰度图像对所述熔池的焊接质量进行检测。
  7. 一种电池焊接方法，用于如权利要求1-6中任一项所述的电池焊接系统，所述方法包括：
    获取所述顶盖和所述壳体之间台阶的轮廓图像；
    基于所述台阶的轮廓图像，得到所述台阶的参数测量值；
    所述伺服运动模组(30)按照预设焊接轨迹运动并基于所述台阶的参数测量值调整所述焊接头(10)处于预设焊接位置，以实现对所述顶盖和所述壳体的焊接。
  8. 根据权利要求7所述的电池焊接方法，其特征在于，所述获取所述顶盖和所述壳体之间台阶的轮廓图像，包括：
    获取所述顶盖的点云图像和所述壳体的点云图像；
    对所述顶盖的点云图像和所述壳体的点云图像进行重建，得到所述台阶的轮廓图像。
  9. 根据权利要求7或8所述的电池焊接方法，其特征在于，所述基于所述台阶的轮廓图像，得到所述台阶的参数测量值，包括：
    基于所述台阶的轮廓图像，得到所述台阶的宽度和高度；
    基于所述宽度和所述高度，得到所述台阶的中心点坐标。
  10. 根据权利要求7-9中任一项所述的电池焊接方法，其特征在于，所述在所述伺服运动模组(30)按照预设焊接轨迹的运动的过程中，基于所述台阶的参数测量值调整所述焊接头(10)处于预设焊接位置，以实现对所述顶盖和所述壳体的焊接，包括：
    基于所述预设焊接轨迹和所述中心点坐标，在所述伺服运动模组(30)按照预设焊接轨迹的运动的过程中，确定所述焊接头(10)的预设焊接位置，其中，所述预设焊接轨迹基于所述顶盖的边缘和所述壳体的边缘得到；
    控制所述焊接头(10)，对所述顶盖和所述壳体进行焊接并在所述台阶内形成熔池。
  11. 根据权利要求7-10中任一项所述的电池焊接方法，其特征在于，所述方法还包括：
    在所述伺服运动模组(30)按照预设焊接轨迹的运动的过程中，获取所述轮廓仪(20)对所述顶盖和所述壳体的熔池的灰度图像；
    基于所述熔池的灰度图像，确认对所述台阶和所述壳体的焊接质量。
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CN118848344A (zh) * 2024-07-05 2024-10-29 珠海市信科自动化设备有限公司 基于图像分析的焊接机器人焊接质量检测系统及方法
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