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InFly Laser Welding stands for intelligent, optically guided, on-the-fly laser welding of battery cell connectors. This innovative technology provides automated optical measurement, real-time data processing and optically guided laser welding at unprecedented speeds, ensuring safe, efficient and high quality production processes.
In the fast-evolving battery industry, precision in manufacturing is crucial for the performance and reliability of battery modules and packs. These systems consist of multiple cells interconnected through laser welding, where even minor misalignments can compromise the entire battery's efficiency and safety. Intelligent optical laser welding, combined with AI-based inspection, addresses this challenge by ensuring extreme precision in weld placement. This not only improves the manufacturing process but also guarantees the long-term reliability and safety of battery packs, meeting the high standards demanded by different industries such as electric vehicles and renewable energy.
Automated Optical Measurement precisely captures the actual position of the weld spot before welding. This measurement data serves as the basis for the subsequent correction of the weld seam. Using our scanner optics, the weld seam is adjusted in real time to ensure maximum precision and optimal alignment. This automated process enhances manufacturing quality and efficiency.
Optically guided laser welding on the fly allows for continuous welding at speeds up to 1000 mm/sec, achieving up to 10 welds per second with real-time corrections. The system’s continuous motion ensures that in the event of a scan system failure, the battery remains undamaged.
Our intelligent weld correction system provides precise, real-time adjustments for optimal weld placement. The system automatically detects battery poles and contact systems, calculates the optimal weld position, and dynamically adjusts the weld shape. This enables up to 10 welds and corrections per second, increasing productivity and minimizing misalignment. Continuous quality monitoring ensures consistent, high-quality results.
AI-based weld seam inspection leverages advanced 2D and 3D imaging systems to automatically inspect weld seams right after the welding process. By integrating image processing with built-in Artificial Intelligence, the system allows process engineers to train it using both good and bad weld examples, without the need for programming. Designed for ease of use, the system offers high transparency in decision-making and ensures reliable results. Optimized algorithms within the image processing architecture enable short cycle times, ensuring seamless integration into the production process for maximum efficiency
through compensation of product and manufacturing tolerances
through optimized cycle times and higher manufacturing speed
through dynamic welding shape correction
The continuous movement of the laser beam during the laser welding process prevents critical damage in the event of a laser guidance system failure. Dynamic adjustment of the weld seam to the cell's movement avoids overheating and thermal damage to the battery. This ensures the battery remains protected even in case of system failure. The risk of incorrect weld placement is minimized, ensuring precise and reliable welds. Integrated safety features and real-time monitoring enhance process reliability, reduce human error, and improve safety throughout the entire manufacturing process.
Ready to revolutionize your battery production? Join us at CES 2025, from January 7-10 in Las Vegas, to explore how Ai-driven software solutions, innovative process technologies and advanced production equipment can be your game-changer in battery manufacturing.
Sabrina Rathgeber | Battery Production Equipment