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Industrial Technology Research Institute

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A Comprehensive Laser Welding System for Lithium-Ion Power Battery Packs

Technology Overview

A Comprehensive Laser Welding System for Lithium-Ion Power Battery Packs.
A Comprehensive Laser Welding System for Lithium-Ion Power Battery Packs.

Most current battery modules are based on 18650 battery cells with resistance welding, and are used mainly in hand tools. Meanwhile, the small battery module has fewer battery cells and welding joints, and provides a shallow welding depth (the thickness of the tab needs to be < 0.3 mm). Thus, not only is manufacturing slow, but the pattern is only single-point and tab materials are limited to nickel and ferrous materials. The industry is gradually developing large-scale electric vehicles and energy storage; traditional battery cells are being replaced by large-capacity square cells, and thicker copper, aluminum (> 0.5mm) and other high conductivity and difficult welding metals are being adopted as tab materials. Existing resistance welding therefore cannot meet current requirements.

In order to solve this problem, intelligent laser welding derives from direct problem simulation, inverse problem simulation, and experimental data. Its welding technology greatly shortens the process adjustment time of 60%, and predicts post-welding quality in order to meet the energy storage demands of large-scale electric vehicles. When this technology is utilized to manufacture battery modules for electric buses, prototype vehicles are operational for nearly two years, and the modules meet original stability criteria. Unsurprisingly, the technology is becoming attractive to battery module customers, and has prompted industry to develop domestic intelligent laser welding battery module equipment. It is expected to also be applied in future industrial developments, including sustainable large-scale energy storage ecosystems.

Features & Innovation

  • Laser welding of metals
  • Laser welding of lithium battery module
  • Homogeneous/heterogeneous laser welding of various metals
  • Combine the cloud-based simulation of the heterogeneous materials welding function and the expandable predictability of the welding morphology and the strength after experimental verification, to establish on-site process parameters
  • Addable quality inspection module
  • Can be integrated with the front and rear production lines

Applications & Benefits

This technology has been applied in the production of electric bus power battery packs (300 kW), UPS energy storage cabinets (20kW). Mass production of mobile scooter/UAV power battery packs (2.5kW) will be introduced in the first half of 111.

A Comprehensive Laser Welding System for Lithium-Ion Power Battery Packs.
A Comprehensive Laser Welding System for Lithium-Ion Power Battery Packs.