CN101297194A - 激光焊接电池模块外壳部件的红外线热成像 - Google Patents

激光焊接电池模块外壳部件的红外线热成像 Download PDF

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CN101297194A
CN101297194A CNA2006800395029A CN200680039502A CN101297194A CN 101297194 A CN101297194 A CN 101297194A CN A2006800395029 A CNA2006800395029 A CN A2006800395029A CN 200680039502 A CN200680039502 A CN 200680039502A CN 101297194 A CN101297194 A CN 101297194A
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module
characteristic signal
thermal imaging
weld seam
hot characteristic
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塞蒂施·阿南撒拉曼
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Robert Bosch Battery Systems LLC
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Cobasys LLC
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/44—Resins; Plastics; Rubber; Leather
    • G01N33/442—Resins; Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7879—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path
    • B29C65/7882—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path said parts to be joined moving in a circular path
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8261—Testing the joint by the use of thermal means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B29C66/612—Making circumferential joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N25/00—Investigating or analyzing materials by the use of thermal means
    • G01N25/72—Investigating presence of flaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/952—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the wavelength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7146—Battery-cases

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Abstract

一种用于电池模块外壳的热成像系统，该电池模块外壳包括第一和第二电池模块外壳部件且在这些电池模块外壳部件之间形成焊缝，所述热成像系统包括热成像相机，该热成像相机在焊缝形成后一段预定时间内聚焦于所述第一和第二电池模块外壳部件上并获得热特征信号。控制模块包括接收热特征信号并在所述热特征信号中定位预定参考点的图像处理模块。图像比较模块接收热特征信号并利用预定参考点将热特征信号与样板特征信号进行比较而检验焊缝结构的完好性。图像比较模块计算热特征信号与样板特征信号的偏差的相对量度，在偏差的相对量度大于预定值时确定焊缝存在缺陷。

Description

激光焊接电池模块外壳部件的红外线热成像
技术领域
本发明涉及塑料焊接(plastic welds)的热成像，更具体地说，涉及用于电池模块外壳中的热塑性塑料部件的红外线热成像。
背景技术
电池模块外壳容纳有一或多个用来提供电能的电池组电池(batterycells)。例如，电池模块外壳可包括多个串联连接的电池组电池以提供期望的电压。在某些情况下，电池组电池包括如氢氧化钾之类的液体材料且需要与电池模块的外部以及单个电池之间提供气密封以防止短路。另外，电池模块经常用在物理上不稳定的环境中，例如用在混合动力机车应用中。因此，电池模块外壳通常包括如共混聚合物之类的热塑性材料。由于电池模块外壳往往包括至少两个接口部件，经常需要焊接，以便在多个部件之间形成密封。
理想的是，这种焊接形成电绝缘的电池盒(cell pockets)。但是，被用来制造电池模块外壳的塑料部件中的变化可能在缺陷区形成薄弱部分或者甚至不可能形成焊缝。例如，可能在成型工艺中或在运输中或塑性部件的处理过程中发生变化。一种解决方案是，采用质量控制和检查技术检测外部泄漏和/或识别薄弱的焊缝。但是电池模块外壳的外部检查识别不出不明显可见的内部泄漏或薄弱的焊缝。另外，人工检查每个制成的塑料外壳部件的每条焊缝既费用高昂又耗费时间。
发明内容
根据本发明，提供一种用于电池模块外壳的热成像系统，该电池部件外壳包括第一和第二电池模块外壳部件，在这些电池模块外壳部件之间形成焊缝，所述热成像系统包括热成像相机，该热成像相机在焊缝形成后一段预定时间内聚焦于第一和第二电池模块外壳上并获得热特征信号(thermal signature)。控制模块包括接收热特征信号并将预定参考点定位在热特征信号中的图像处理模块。图像比较模块接收热特征信号并利用预定参考点对热特征信号与样板特征信号进行比较以检验焊缝结构的完好性(integrity of the weld)。
在其他一些特性中，热成像相机是红外线热成像相机。图像处理模块使用图像处理算法来定位热和样板特征信号中的共同的结构特征。第一和第二电池模块外壳部件包括聚合物热塑性塑料。电池模块外壳容纳至少一个用于混合动力机车的电池组电池。激光源使激光束聚焦于第一和第二模块外壳部件上以形成焊缝。第一和第二模块外壳部件被固定在包括电机的回转机构上。控制模块包括可调节回转机构位置的回转机构模块，致使在激光源形成焊缝时第一和第二模块外壳部件被定位在激光束的路径上，因此在热成像相机获得热特征信号时，第一和第二模块外壳部件处于热成像相机的视野内。
在本发明的再一些特性中，图像比较模块计算热特征信号与样板特征信号的偏差的相对量度(relative measure)，当偏差的相对量度大于预定值时确定焊缝存在缺陷。数据模块储存样板特征信号。在图像比较模块检验焊缝结构的完好性后，图像比较模块将热特征信号和焊缝完好性的值储存在数据模块内。数据分析模块根据多个被储存在数据模块内的焊缝完好性的值得出焊缝完好性统计量。
通过下文的详细描述将更加清楚本发明的其他应用领域。应理解的是，这些详细描述和显示本发明优选实施例的具体实例只是为了阐述本发明原理而不是对本发明范围的限制。
附图说明
从结合附图的详细描述中可以更好地理解本发明。附图中：
图1为本发明的用于电池模块的塑料外壳部件的热成像系统的功能结构框图；
图2A为单体电池电池模块(single-cell battery module)外壳一实例的前视图；
图2B为单体电池电池模块外壳的侧向横截面图，它示出了塑料电池模块外壳部件之间的接口；
图2C为图2B所示的按比例示出的局部图，它示出了利用激光焊接在塑料外壳部件之间形成的焊缝；
图3A为单体电池电池模块外壳的第一横截面图，它示出了沿两个塑料外壳部件之间的接口的焊缝；
图3B为焊接过程后从顶部看到的图3A所示的单体电池电池模块外壳的热特征信号；
图4示出了热特征信号梯度的一实例，该梯度可确定由于温度变化引起的热特征信号中可见的图像变动；
图5A为单体电池电池模块外壳的第二横截面图，其示出了塑料外壳部件内的缺陷；
图5B示出了图5A中的单体电池的电池模块外壳的从顶部透视的热特征信号，其示出了在缺陷区域内的可见的不一致性；
图6的流程图示出了由热成像系统执行的检测存在缺陷的焊缝的步骤。
具体实施方式
下文描述的优选实施例(一或多个)实质上只是示例性的，它在任何方面对本发明的应用或使用都不起限制作用。为清晰起见，附图中所使用的相同的附图标记表示类似元件。如在这里使用的术语“模块”是指专用集成电路(ASIC)、电路、处理器(共享的、专用的、或处理器组)和执行一或多个软件或固件程序的内存、组合逻辑电路、和/或具有所述功能的其他适当的部件。
现参考图1，用于电池模块外壳12的一示例性热成像系统10包括激光源14、红外线热成像相机16和回转机构18。需焊接的塑料外壳部件12被固定在回转机构18上。例如，回转机构18可使塑料外壳部件12在三个不同位置之间运动。在第一位置，塑料外壳部件12被固定到回转机构18上。然后使塑料外壳部件12运动到第二位置，在该位置激光源14可在两个或多个塑料外壳部件12之间的接合处形成焊缝。最后，使塑料外壳部件12运动到第三位置，在该位置红外线热成像相机16获取热特征信号以校验焊缝的完好性。
控制模块20控制热成像系统10的运行。控制模块20包括回转机构控制模块22，该模块与回转机构18的电机24保持联系并在塑料外壳部件12焊接和热成像过程中调节回转机构18的位置。例如，可对回转机构控制模块22进行编程，以便在每个位置之间使回转机构18转动预定角度。激光控制模块26控制激光源14的工作。例如，激光控制模块26可打开或关闭激光源14并可调节激光源14的工作参数，例如，激光源14发射的激光束28的波长。相机控制模块30控制红外线热成像相机16的工作。例如，相机控制模块30启动或关闭热成像相机16并可调节如分辨率和缩放之类的工作参数。
在一示例性实施例中，塑料外壳部件12包括如共混聚合物之类的热塑性塑料。由于热塑性塑料传导性很差，塑料外壳部件12的焊接温度在一段时间内保持一致。因此，优选在焊接步骤完成后一段预定时间内红外线热成像相机16获取经焊接的塑料外壳部件12的热特征信号。例如，可将红外线热成像相机16设定成焊接步骤完成后五秒钟内获取热特征信号。
图像处理模块32接收来自红外线热成像相机16的塑料外壳部件12相应的热特征信号。数据库34包括与带有预定的符合要求的焊缝的塑料外壳部件相应的样板特征信号。例如，样板特征信号可与带有通过使用显微技术严格检查以保证符合要求的焊缝的塑料外壳部件12相应。样板特征信号包括一或多个与样板特征信号和其他潜在的热特征信号两者共有的结构相应的参考点。因此，图像处理模块32使用图像处理算法来定位与样板特征信号上的参考点相应的热特征信号上的参考点。例如，参考点可以是塑料外壳部件12的可见表面或边缘。
图像比较模块36接收来自图像处理模块32的热特征信号和来自数据库34的样板特征信号。图像比较模块36比较热和样板特征信号，以检测存在缺陷的塑料外壳部件12或薄弱的或不存在的焊缝。例如，图像比较模块36可检测到沿被焊接的塑料外壳部件12的结合处的热特征信号内的可见的不一致性。根据比较，图像比较模块36可确定对塑料外壳部件12满意还是不满意。例如，图像比较模块36可计算热特征信号和样板特征信号的偏差的相对量度。令人满意的热特征信号相应的偏差相对量度小于或等于预定值。例如，可根据期望的容许误差来调节预定值，以检查塑料外壳部件12。
另外，在特征信号比较之后图像比较模块36将热特征信号储存在数据库34中并作出与满意或不满意有关的识别标记。控制模块20包括数据分析模块38，该数据分析模块读取贮存于数据库34中的热特征信号检测结果并进行焊缝完好性统计。例如，数据分析模块38可跟踪出现存在缺陷的焊缝的相对率以便控制质量。
现参考图2A-2C，它们示出了电池模块46的一实例，该模块包括装有电池组电池的内部空腔48。内部空腔48由多个塑料外壳部件50限定，这些外壳部件相互连接且沿塑料外壳部件50之间的结合处焊接在一起。例如，图2C为分别在电池模块46的侧面和顶部塑料外壳部件50-3和50-2之间的结合处54的放大视图52。利用透射激光焊接(through transmission laserwelding，TTLW)工艺将激光束28聚焦于结合处54。例如，激光源14可包括多束激光束28以用于持续照射所需要照射的区域，当然也可用其他激光源结构。加热区58内形成熔池(melt pool)56，激光源14关闭且熔池56冷却时，塑料外壳部件50-2和50-3之间留下结构性结合。
通常由于热塑性塑料具有低传导性而激光源14具有高聚焦能力，加热区58相当小，对内部空腔48内装入的部件危害很小。虽然图2A-2C中示出的电池模块46是单体电池电池模块46，本领域技术人员可以想到，电池模块46可包括各自隔离并串联连接的多个电池组电池。
现参考图3A和3B，为了使激光束28到达塑料外壳部件50之间的结合处54，塑料外壳部件50-4和/或50-3中的至少之一可透过激光束28的波长。尽管也能采用其它波长，在一示例性实施例中，激光束28的波长是在800nm和1100nm之间。激光束28穿透塑料外壳部件50-3以便在塑料外壳部件50之间的结合处54形成加热区58。图3A示出了在焊接前没存在缺陷的塑料外壳部件50，且焊缝沿塑料外壳部件50的周边形成，以在焊接过程中密封电池模块46。图3B示出了塑料外壳部件50的热特征信号66的顶视图。沿电池模块46的周边的焊接点68的温差由热特征信号66上的颜色变动表示。
现参考图4，其示出了在热特征信号66上温度变化表现的热特征信号梯度76的一实例。例如，根据热特征信号梯度76，低于室温的温度在热特征信号66中没有清晰地显出，而用于热塑性塑料的焊接所需的温度则呈现出很深或不透明。因此，如图3B所示，颜色与沿焊接点68的预期温度保持一致。沿塑料外壳部件50的周边焊接点68的内部部分78(如图3B所示)呈现很深颜色，而在离开内部部分78时颜色变浅。
现参考图5A和5B，电池模块86的塑料外壳部件50-5存在缺陷。例如，在塑料外壳部件50-5中的缺口(chip)88可妨碍两个塑料外壳部件50-3和50-5之间的结合处54上形成结构上完好的焊缝(sound weld)。图5B示出了图5A中的电池模块86的热特征信号90的顶视图。沿焊接点68的热特征信号90的颜色的一致性在缺口88所在区域92被打破。没达到焊接点68的内部部分78的常规深颜色并被与焊接点68的外部部分94的颜色一致的较浅的颜色代替。由图像处理模块32执行的图像处理算法检测在热特征信号90内的不一致性并在将热特征信号90储存到数据库34之前将电池模块86确定为存在缺陷。
现参考图6，热成像算法开始于步骤102。在步骤104，控制部分确定需要焊接的下一个塑料外壳部件50是否到位。若没有就位，控制循环到步骤104。如果就位的话，在步骤106，回转机构控制模块22调节回转机构18的位置从而使塑料外壳部件50处于激光源14之下以便焊接。在步骤108，激光控制模块26触发激光源14以形成焊缝。在步骤110，回转机构控制模块22调节回转机构18的位置，使塑料外壳部件50处于红外线热成像相机16的视野内。在步骤112，相机控制模块30启动红外线热成像相机16，以获得塑料外壳部件50的热特征信号90。
在步骤114，图像处理模块32接收热特征信号90并将参考点定位成与样板特征信号66一致。在步骤116，图像比较模块36分别比较热特征信号90和样板特征信号66，并计算热特征信号90与样板特征信号66的偏差的相对量度。在步骤118，控制部分确定相对偏差是否大于预定值。如果大于预定值，控制部分进行步骤120。如果不大于预定值，在步骤122图像比较模块36确定电池模块86符合要求且控制部分进行步骤124。在步骤120，图像比较模块36确定电池模块86存在缺陷，而控制部分进行步骤124。在步骤124，图像比较模块36将热特征信号90储存在数据库34中控制过程结束。
本发明的热成像系统10可用来检验如用于混合动力机车的电池组之类的电池模块86的塑料外壳部件50焊接是否适当。热成像系统10是非破坏性的且可与激光焊接处理过程完全集成在一起，以便直接确定存在缺陷的焊缝，这将降低费用并减少制造时间。
本领域技术人员从前面的描述中可以理解的是，可将本发明的主要教导应用在各种形式中。因此，尽管通过具体的实例对本发明进行了描述，但对本领域技术人员来说，通过研究本发明的附图、说明书文字部分和所附的权利要求，可显而易见地对本发明作出其他改进，本发明实际保护范围应不受此限制。

Claims (20)

1.一种用于电池模块外壳的热成像系统，该电池模块包括第一和第二电池模块外壳部件，在这些电池模块外壳部件之间形成焊缝，所述热成像系统包括：
热成像相机，其在形成焊缝后一段预定时间内聚焦于所述第一和第二电池模块外壳部件上并获得热特征信号；
控制模块，其包括：
图像处理模块，该模块接收所述热特征信号并在所述热特征信号中定位预定的参考点；及
图像比较模块，该模块接收所述热特征信号，并利用所述预定参考点将所述热特征信号与样板特征信号进行比较，以检验所述焊缝结构的完好性。
2.如权利要求1所述的热成像系统，其中，所述热成像相机是红外线热成像相机。
3.如权利要求1所述的热成像系统，其中，所述图像处理模块使用图像处理算法来定位在所述热特征信号和所述样板特征信号两者中共同的结构特性。
4.如权利要求1所述的热成像系统，其中，所述第一和第二电池模块外壳部件包括聚合物热塑性塑料。
5.如权利要求1所述的热成像系统，其中，所述电池模块外壳容纳至少一个用于混合动力机车的电池组电池。
6.如权利要求1所述的热成像系统，其中，还包括：
激光源，其使激光束聚焦于所述第一和第二模块外壳部件上以形成焊缝；及
回转机构，其包括电机，该回转机构上固定有所述第一和第二模块外壳部件，
其中所述控制模块包括回转机构模块，该回转机构模块调节所述回转机构的位置，使得所述激光源形成所述焊缝时所述第一和第二模块外壳部件被定位在所述激光束的路径上，致使所述热成像相机获得所述热特征信号时所述第一和第二模块外壳部件被定位在所述热成像相机的视野内。
7.如权利要求1所述的热成像系统，其中，所述图像比较模块计算所述热特征信号与所述样板特征信号的偏差的相对量度，在所述偏差的相对量度大于预定值时确定所述焊缝存在缺陷。
8.如权利要求1所述的热成像系统，其中，还包括储存所述样板特征信号的数据模块，其中在所述图像比较模块检验所述焊缝的结构完好性后，所述图像比较模块将所述热特征信号和与所述热特征信号相关的焊缝完好性的值贮存在所述数据模块中。
9.如权利要求8所述的热成像系统，其中，还包括数据分析模块，该模块根据储存在所述数据模块中的多个焊缝完好性的值得出焊缝完好性统计量。
10.一种电池模块外壳焊接系统，包括：
激光源，其使激光束聚焦于第一和第二电池模块外壳部件之间的结合处，以便在所述第一和第二电池模块外壳部件之间形成焊缝；
热成像相机，其在所述焊缝形成后一段预定时间内聚焦于所述第一和第二电池模块外壳部件上并获得热特征信号；
控制模块，其包括：
图像处理模块，该模块接收所述热特征信号并将预定的参考点定位于所述热特征信号中；及
图像比较模块，该模块接收所述热特征信号并利用所述预定的参考点将所述热特征信号与样板特征信号进行比较，以检验所述焊缝结构的完好性。
11.如权利要求10所述的电池模块外壳焊接系统，其中，还包括：
回转机构，其包括电机，所述第一和第二模块外壳部件被固定在该回转机构上，
其中所述控制模块包括调节所述回转机构位置的回转机构模块，使得所述激光源形成所述焊缝时，所述第一和第二模块外壳部件被定位在所述激光束的路径上，当所述热成像相机获得所述热特征信号时，所述第一和第二模块外壳部件处于所述热成像相机的视野内。
12.一种用于操作热成像系统的方法，该系统用于包括第一和第二电池模块外壳部件且在所述模块之间形成焊缝的电池模块外壳，该方法包括：
在所述焊缝形成后一段预定时间内获取所述焊缝的热特征信号；
利用图像处理算法在所述热特征信号中定位预定的参考点；及
将所述热特征信号与样板特征信号进行比较以检验所述焊缝结构的完好性。
13.如权利要求12所述的方法，其中，还包括使用红外线热成像相机来获得所述热特征信号。
14.如权利要求12所述的方法，其中，还包括利用图像处理算法来定位在所述热特征信号和所述样板特征两者信号中共同的结构特性。
15.如权利要求12所述的方法，其中，所述第一和第二电池模块外壳部件包括聚合物热塑性塑料。
16.如权利要求12所述的方法，其中，还包括在所述电池模块外壳中容纳至少一个用于混合动力机车的电池组电池。
17.如权利要求12所述的方法，其中，还包括：
将所述第一和第二模块外壳部件固定在回转机构上；
使激光束聚焦于所述第一和第二模块外壳部件上以形成焊缝；
调节所述回转机构的位置使得焊缝形成时所述第一和第二模块外壳部件被定位在所述激光束的路径上；及
调节所述回转机构的位置，使所述第一和第二模块外壳部件处于有效视野内以获得所述热特征信号。
18.如权利要求12所述的方法，其中，还包括：
计算所述热特征信号与所述样板特征信号的偏差的相对量度；及
当所述偏差的相对量度大于预定值时确定所述焊缝存在缺陷。
19.如权利要求12所述的方法，其中，还包括：
将所述样板特征信号储存在数据库中；
检验所述焊缝的结构完好性；及
将所述热特征信号和与所述热特征信号相关的焊缝完好性的值储存在所述数据库中。
20.如权利要求19所述的方法，其中，还包括根据储存在所述数据库中的多个焊缝完好性的值得出焊缝完好性统计量。
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