Introduction
In the field of power battery manufacturing, the welding quality of tabs directly determines the safety performance and service life of battery cells. Traditional inspection methods mainly rely on manual sampling inspection or destructive testing, which are not only inefficient but also carry the risk of missed defects. The NewOCT Galvo Welding Detection System, based on Optical Coherence Tomography (OCT) technology, achieves non-destructive full inspection of weld penetration with its micron-level resolution, driving the power battery manufacturing industry into a new era of intelligent and high-precision production.
I. Technological Breakthrough: Core Capability of Micron-Level Precision
The NewOCT Weld Penetration Detection System is a one-stop integrated solution for the welding and inspection of battery cell tabs. It includes: NewOCT Galvo Welding Head, Welding Control System, and OCT Detection System, enabling simultaneous welding and weld penetration inspection of battery cell tabs.
- Ultra-Precision Detection Technology
- Hardware Performance: The axial resolution of the OCT system is ≤ 0.02mm (20μm), accurately identifying defects during welding such as insufficient/excessive weld penetration, cold welding, and missing welds.
- Detection Range: The maximum measurement range is ≥ 12mm, covering all application scenarios of tab welding, with a weld penetration detection accuracy of ≤ 10%.
2.Integrated Synchronous Welding and Inspection
- Integrated Design: Integrates the NewOCT Galvo Head and laser welding system, completing weld penetration inspection simultaneously with the welding process. This eliminates the time delay and misjudgment risk of traditional offline inspection.
- Process Adaptability: Supports multiple oscillation waveforms including linear, sine, figure-of-eight, U-shaped, and arc, adapting to high-efficiency tab welding processes (flying welding speed up to 200mm/s). Detection accuracy remains unaffected by welding speed.
II. System Advantages: Full-Process Closed-Loop Control and Intelligence
- Full-Process Quality Control
- Pre-Welding: A reserved height measurement interface enables dynamic focus compensation, ensuring welding consistency.
- In-Welding: Real-time weld penetration monitoring, combined with triple safety interlocks (position deviation, laser emission duration, system status), guarantees zero risk during 8kW full-power operation.
- Post-Welding: Data traceability and recipe-based management, supporting one-click calling of multiple parameter recipes.
2.Industry 4.0 Compatibility
- Supports industrial protocols such as EtherCAT, Profinet, and Modbus TCP, directly connecting to the MES system to realize bidirectional interaction between welding parameters and detection data.
- Optional field lens contamination detection and power monitoring devices are available to enhance process controllability.
III. Industry Value: Comprehensive Upgrade from Cost Reduction to Reliability
1.Economic Benefits
Labor costs reduced by 90%, material waste lowered by 80%, rework rate decreased by 50%, and the risk of batch scrapping completely eliminated.
2.Quality Assurance
The NewOCT Weld Penetration Detection System achieves full closed-loop quality control of the welding process through high-precision sensors (real-time monitoring of position, temperature, and power) and dynamic compensation algorithms.
3.Technological Prospects
The dedicated NewOCT Galvo Head and custom-developed algorithms can be extended to fields requiring micron-level precision such as precision electronics (FPC welding) and medical devices.
