1. Welding: battery pack "Vascular Suture"

II. Behind 0.02mm: Full Link Control from equipment to process

achieving a welding accuracy of 0.02mm is not the credit of a single device, but a systematic project of the whole link.

The accuracy of incoming materials is the premise. Cell the flatness of pole and the dimensional tolerance of busbar directly affect the consistency of welding gap. Aggregate energy new energy performs flatness control of ± 0.01mm on the incoming materials of suppliers, and returns all batches beyond the range. "The upstream 0.01mm is the foundation of our downstream 0.02mm. "The quality engineer explained.

The stability of laser and optical system is the core. The new energy source adopts imported fiber laser, and the power fluctuation is controlled within ± 1%. Oscillating mirror the positioning accuracy of the scanning system reaches ± 0.005mm, and the trajectory offset caused by thermal deformation is corrected in real time with the closed-loop feedback algorithm. During the welding process, the high-speed camera captures the molten pool form at a speed of 5,000 frames per second, and the AI model determines whether the penetration reaches the standard in real time.

The rigid design of fixture is the key. Battery pack micro-scale deformation will be generated during the welding process due to heat input. The fixture for gathering energy new energy adopts the combination of aviation aluminium alloy and ceramic positioning pin. The distribution of clamping force is optimized by finite element method to restrain the welding deformation within 0.015mm.

iii. 100% detection: do not allow a defective solder joint to flow out

after welding is completed, the inspection process is also rigorous.

AI visual inspection scan the weld surface with a resolution of 0.01mm to identify appearance defects such as splash, depression and undercut, and the detection rate exceeds. "We have trained more than 500000 defective samples, and the sensitivity of the model to tiny cracks is ten times higher than that of human eyes. "Visual algorithm engineers show the detection interface, and each suspicious solder joint is automatically marked, graded and traced.

X-Ray nondestructive testing then penetrate the surface and examine the depth of penetration, pores and unfused areas inside the weld. New energy sources perform 100% full inspection on key solder joints instead of common spot inspection in the industry. X-Ray images are bound to each battery pack qr code, and the archiving period is not less than 15 years.

Tension test it is the final mechanical verification. The welding spot is randomly selected for destructive stretching every shift, and the fracture position must be located in the base metal instead of the weld-this means that the welding strength is higher than the base metal itself, reaching the standard of "equal strength connection.

the improvement of welding precision brings not only the quality improvement of a single solder joint, but also the system-level safety transition.

Internal resistance consistency is the primary benefit. For every 0.01mm reduction in welding gap, the contact resistance can be reduced by about 5%, the distribution of internal resistance in the whole package is more uniform, and the calorific value during charging and discharging is significantly reduced. The measured data show that the temperature rise of welding spot is above 3℃ lower than the average level of the industry when the battery pack of the new energy is charged at 4C fast.

Vibration durability is another guarantee. In the 100000-kilometer vibration test of the whole vehicle, battery pack of the welding precision reaches the standard, and the fatigue failure rate of solder joints is zero; However, micro-crack propagation may occur after tens of thousands of kilometers for products with poor precision control.

More importantly, the accuracy standard of 0.02mm is conducting upstream and downstream. Gather energy and new energy to build a "precision alliance" with electric core factories and material suppliers to narrow the tolerance range of the entire supply chain. "This is not cost, but investment. "The Process Director concluded," every penny saved in the upstream may be returned at a cost of ten times lower. "

0.02mm, a seemingly insignificant number, but carrying gatheringThe ultimate pursuit of new energy for welding technology. In this production line, the laser beam shuttles between cell with micron precision, and AI algorithm examines each molten pool at millisecond speed, the detection system intercepts every flaw with a zero tolerance attitude.