·激光器、加工头和传感器的一站式方案提高了生产力

·创新焊接系统加快了电动汽车电池的制造速度

·电池质量进一步提高，废品率得以下降

　　电池中国获悉，近日，全球高科技公司德国通快集团(TRUMPF)在慕尼黑光博会上将展示一种新型焊接系统，旨在提高电动汽车电池生产的效率。该系统用于焊接汇流排(又称busbar)，也就是连接电芯与电芯之间的条状连接片。以 8kW 的 TruDisk 8000 激光器为核心，这种新型系统包括新型加工镜头、新型熔深检测传感器和软件。所有部件都经过优化，相互匹配。该系统加快了电芯的生产速度，降低了废品率。焊接质量的提高进一步降低了连接电阻，从而提升了电动汽车的续航能力。

01

汇流排焊接系统的核心—— TruDisk 8000 激光器

　　TruDisk 8000 高功率固体激光器兼具 8 kW 的高能量输出和优异的光束质量。有了这些特性，它可以兼容 50 微米的激光光缆，在工件表面释放高能激光。得益于高能量转化率、节能脉冲功能和智能能量管理，TruDisk 在每种激光模式下都能以更低成本运行。同时，它的内部设计也非常智能化，多种传感器能跟踪所有关键参数并提供状态检测数据。紧凑的外形、更少的占地面积和非常坚固的设计都让 TruDisk 激光器与众不同。？

图1 电池汇流排焊接系统的核心是通快 TruDisk 8000 激光器

02

新一代 PFO33 扫描振镜

　　新型焊接系统的关键之一是通快的第三代扫描振镜。这些扫描振镜带有一个智能控制系统，可与激光器实时通信。这确保了在包含多个焊接工序的高速量产制造过程中，每个焊接过程都能精确执行。该光学系统还具有新的透镜，可以承受亮度极高的光源。因此，像 TruDisk 8000 这样的产品可以在整个 PFO33 扫描振镜的加工范围中使用。另一个突出的特点是，通快第三代扫描振镜可配备一个特殊镜头，该选配件可实现多个电芯汇流排可以在更大的扫描区域内进行焊接，而不需要重新定位加工镜头或组件。该加工镜头的镜片可以灵活移动。这为电池制造商在设计焊接工艺和制图方面提供了更大的余地，也提高了生产效率。

图2 通快新一代 PFO33 扫描振镜

03

新型VisionLine OCT Check 熔深检测传感器

　　VisionLine OCT Check传感器在整个焊接过程中检测熔池深度，以确保激光器始终按照预设的参数进行焊接。它还可以检查固化的焊缝是否存在几何形状上的不一致。这就实现了单个汇流排焊点的高度重复性，并对每个部件和每条焊缝进行持续的质量保证，最大限度地减少了对人工质量检查的需求。更重要的是，从传感器系统获得的质量数据可以在零件加工完成的那一刻归档。VisionLine OCT Check 易于使用，用户可通过一个直观的界面进行快速编程。

One-stop solution for lasers, processing heads and sensors increases productivity

Innovative welding system speeds up EV battery manufacturing

The battery quality is further improved, and the scrap rate is reduced


Battery China has learned that recently, the global high-tech company TRUMPF will showcase a new welding system at the Munich Light Expo, designed to improve the efficiency of electric vehicle battery production. The system is used to solder bus bars (also known as busbars), which are strip-shaped connectors that connect cells to cells. With an 8kW TruDisk 8000 laser at its core, the new system includes a new machining lens, a new penetration detection sensor and software. All components are optimized to match each other. The system speeds up cell production and reduces scrap rates. The improved welding quality further reduces the connection resistance, thereby increasing the range of electric vehicles.


01

The Heart of a Busbar Welding System - the TruDisk 8000 Laser


The TruDisk 8000 high-power solid-state laser combines a high energy output of 8 kW with excellent beam quality. With these features, it is compatible with 50 micron laser fiber optic cables, which emit high-energy laser light on the workpiece surface. Thanks to high energy conversion rates, energy-efficient pulsing capabilities, and intelligent energy management, TruDisk operates at a lower cost in every laser mode. At the same time, its internal design is also very intelligent, and various sensors can track all key parameters and provide status detection data. A compact form factor, reduced footprint, and a very robust design make TruDisk lasers unique. ?


A new breakthrough in the battery life of electric vehicles, TRUMPF released the battery bus welding system

Figure 1 The heart of the battery busbar welding system is the TRUMPF TruDisk 8000 laser


02

New Generation PFO33 Scanning Galvo


One of the keys to the new welding system is TRUMPFs third-generation galvanometer. These galvanometers feature an intelligent control system that communicates with the laser in real time. This ensures that each welding process can be performed with precision during high-speed mass-production manufacturing processes involving multiple welding operations. The optical system also features new lenses that can withstand extremely bright light sources. As a result, products like the TruDisk 8000 can be used in the entire processing range of the PFO33 galvanometer. Another outstanding feature is that the TRUMPF 3rd generation scanning galvanometer can be equipped with a special lens, this option allows multiple cell busbars to be welded over a larger scanning area without the need to reposition the machining lens. or components. The lens of this processing lens can move flexibly. This gives battery manufacturers more leeway in designing welding processes and drawings, and also increases production efficiency.


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Figure 2 TRUMPFs new generation PFO33 scanning galvanometer


03

New VisionLine OCT Check Penetration Sensor


The VisionLine OCT Check sensor detects the weld pool depth throughout the welding process to ensure that the laser is always welding according to preset parameters. It can also inspect cured welds for geometric inconsistencies. This enables a high degree of repeatability of individual busbar solder joints and continuous quality assurance for each component and each weld, minimizing the need for manual quality checks. Whats more, the quality data obtained from the sensor system can be archived the moment the part is machined. The VisionLine OCT Check is easy to use, allowing users to quickly program through an intuitive interface.