- E-Mobility
- Battery cell | Cell assembly
- Welding on the contact tab
Welding on the contact tab
In this process step, the power lugs of the electrode stack are welded to the contact tabs (cell tabs). The power lugs are shortened to a uniform length by a blade cut before the welding process. For welding, the cell tabs are placed on the power lugs and fixed in place using a holding device.
| System availability | Performance | Quality | |
|---|---|---|---|
| Monitoring suction pressure |  |
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| Measuring a pneumatic cylinder | |
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| Position detection: | |
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| Energy monitoring | |
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| Position detection of the contact tabs | |
Ensuring Secure Gripping of the Cells
The negative pressure on the suction nozzles makes it possible to fix the cell in place so that ultrasonic welding can be started safely. Monitoring and control of a constant suction pressure is necessary for precise positioning of the electrode sheet.
Enhancing performance
Solution
Series PN vacuum sensors reliably detect the required negative pressure. If the minimum values are not reached, the suction gripper remains in its initial position to prevent damage to the workpieces and systems. If the pressure sensors need to be replaced, the set parameters can be copied to the new sensor via IO-Link. This saves time and prevents possible setting faults.
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Measuring a pneumatic cylinder
Reliably Detecting the Piston Position in Pneumatic Cylinders
Many different pneumatic cylinders are used to perform precise recurring linear movements. To detect end piston positions in pneumatic cylinders reliably and precisely, cylinder sensors are used.
Enhancing performance
Solution
Cylinder sensors from ifm reliably detect the piston position. They can be fixed to almost any T-slot, C-slot, clean-line, tie rod, integrated profile or trapezoidal slot cylinder. The self-adhesive fixing mechanism enables fast assembly and easy adjustment. That saves time when exchanging devices and increases system availability.
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Ensuring Exact Positioning of Components
It is important to coordinate automated work steps to ensure efficient production and prevent rejects. To start the welding process, in addition to fixing the cells in place, the position must also be detected. The welding process does not start until defined positions are reached.
Enhancing performance
Solution
ifm's photoelectric sensors in small design or fibre optics with fibre-optic amplifier ensure reliably detection, even in constrained spaces.
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Monitoring Compressed Air Consumption Reliably and Reducing Energy Consumption
Compressed air is indispensable in today's producing industries. It is also one of the most expensive forms of energy. Efficiently measuring compressed air can lower energy consumption and costs significantly.
Enhancing performance
Solutions
The SD's precise volumetric flow monitoring allows for leakage detection and energy cost savings. In addition, the unit's high repeatability enables exact allocation of the costs of compressed air to the respective production line as well as optimised product cost calculation.
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Position detection of the contact tabs
Detecting Incorrectly Welded Contact Tabs
Despite the precise and reliably controlled process of attaching the contact tab, the deviation of tolerance in the position of the contact tabs may be too great. This can impair quality in the subsequent processing of the faulty cell for battery modules and packs.
Quality assurance
Solution
An incorrect position of contact tabs can be detected at an early stage with the object detection sensor from ifm. In combination with the matching software, the O2D offers precise object detection and inspection by means of a blob analysis.
