EP4106945A1

EP4106945A1 - Method for analysing a weld during laser welding of workpieces

Info

Publication number: EP4106945A1
Application number: EP21706560.6A
Authority: EP
Inventors: Jens REISER; Lutz König; Erich Schauer; Thorsten Lorenz; Jonas NOLTE; Alexis Donke; Sascha GRAU; Rüdiger MOSER; Wei Quang DUONG; Matthias STREBEL; Birmanns STEFAN
Original assignee: Precitec GmbH and Co KG
Current assignee: Precitec GmbH and Co KG
Priority date: 2020-02-20
Filing date: 2021-02-18
Publication date: 2022-12-28
Also published as: DE102020104462A1; CN115335183A; KR20220137125A; US20230073549A1; JP2023514403A; WO2021165380A1

Abstract

The invention relates to a method for analysing a weld during laser welding of workpieces (30a, 30b), comprising: - detecting (S1) a first measurement signal (P1, P2) for process radiation generated during laser welding; - detecting (S2) a second measurement signal (P3) for radiation reflected by the workpieces (30a, 30b); - determining (S3), on the basis of the first measurement signal (P1, P2), whether there is a gap (S) between the workpieces (30a, 30b); and - if it is found that there is a gap (S), determining, on the basis of the second measurement signal (P3), whether a weld exists.

Description

Method for analyzing a welded joint during laser welding of workpieces

The present invention relates to a method for analyzing a welded joint during laser welding of workpieces, in particular during the laser welding process.

Background and prior art

In a laser processing system for processing a workpiece by means of a laser beam, the laser beam emerging from a laser light source or one end of a laser guide fiber is focused or bundled onto the workpiece to be processed with the aid of beam guidance and focusing optics. The processing can include laser welding, for example. The laser processing system can comprise a laser processing device, for example a laser processing head, in particular a laser welding head. Especially when laser welding a workpiece, it is important to continuously monitor the welding process in order to ensure the quality of the processing. This includes the detection of machining errors.

A machining process is typically monitored by recording and analyzing various parameters of a process radiation, also known as process beam, process light or process emission. These include, for example, plasma radiation generated by the machining of workpiece surfaces, process emissions in the infrared range of light, such as temperature radiation, or process emissions in the visible range of light. This is followed by an assessment in which the corresponding measurement signals are checked to determine whether certain conditions are met. If one or more measurement signals meet predefined conditions during processing, an error signal is output. Accordingly, a machined workpiece can be marked as “good” or “good part” (i.e. suitable for further processing or sale) or as “bad” or “bad part” (i.e. as reject). The continuous monitoring of a machining process typically takes place in real time while the machining process is being carried out, and is therefore also referred to as online process monitoring or in-line process monitoring.

The application DE 10 2019 122 047 describes a sensor module for monitoring laser welding processes, which has several detectors or sensors that detect various parameters of the process radiation and output them as a measurement signal.

Batteries play a central role in the field of electromobility. Individual battery cells, also known as “battery cells”, are connected to one another, ie contacted. A A combination of several battery cells is called a "battery module". The connection is mostly done by laser welding. The arresters of the battery cells are connected to one another by laser welding, typically in a lap joint. The weld seams have a so-called “I-seam” geometry, for example. Materials are usually aluminum and copper. Typical compounds or material combinations are copper-copper, aluminum-aluminum and copper-aluminum. When connecting battery cells to form battery modules and thus for successful module construction, it is essential that there is electrical contact between the connected workpieces, ie that current can flow between the connected workpieces or via the weld seam. Contacting is only successful in this case.

Typical defects can occur during laser welding, especially in the lap joint with I-seams. This includes a gap between the workpieces. This error can be tolerated if there is a welded connection, i.e. the gap is bridged by melted material of the workpieces, i.e. if there is still electrical contact between the workpieces to be welded despite the existing gap. This is also referred to as “welding with gap bridging” or “gap with (electrical) contact”. Another typical error pattern is called "false friend" or "false friend". There is a gap between the connected workpieces, the gap not being bridged and therefore no (electrical) contact between the workpieces. This is also known as “welding without bridging a gap” or “gap without (electrical) contact”. A gap between the workpieces should therefore be as small as possible or should be as small as possible.

In the case of a top view, especially during an inspection after the laser welding has been carried out, it is not possible to distinguish visually whether a proper weld, ie a welded joint without a gap, also referred to as a "good weld" or a "weld with a zero gap", is present, or whether a weld with a gap but with a gap bridging, ie a weld with a gap, or a weld with a gap but without a gap bridging. There is currently no way to identify a wrong friend during the welding process.

Disclosure of the invention

It is an object of the present invention to analyze or assess a welding connection between workpieces easily and quickly during laser welding. It is an object of the present invention, in laser welding, to enable a simple and quick differentiation between a weld without a gap and a weld with a gap.

In particular, it is an object of the present invention to detect in a weld with a gap between the workpieces whether a gap with a gap bridging, ie with electrical contact between the workpieces, or a gap without connection, ie without electrical contact between the workpieces , is present.

It is also an object of the present invention to enable the analysis or the distinction in real time, in particular during the laser welding process of the welded joint.

These objects are achieved by the subject matter of the independent claim. Advantageous refinements and developments are the subject of dependent claims.

The invention is based on the idea of acquiring and suitably evaluating measurement signals, especially during the laser welding process, based on process radiation generated during laser welding of welding connections and back-reflected laser radiation, in order to analyze or differentiate between welds and welded connections. The measurement signals can be detected by sensors, in particular by photodiodes.

According to one aspect of the present invention, a method for analyzing or assessing a welded joint during laser welding of workpieces is specified, the method comprising the following steps: acquiring a first measurement signal of a process radiation generated during laser welding; Detection of a second measurement signal of radiation reflected from the workpieces, in particular a laser radiation reflected from the workpieces; Determining, based on the first measurement signal, whether there is a gap between the connected workpieces; and if it is determined that there is a gap, determining, based on the second measurement signal, whether a weld connection or a gap bridging exists. The reflected radiation can include at least one of the following: reflected laser radiation of the (machining laser beam, reflected LED radiation or reflected LED light, and reflected pilot laser radiation. The method can further include: irradiating an LED radiation or illuminating with LED light, in particular illuminating a current processing position or illuminating an area around a current point of impact of a processing laser beam. The method can further include: irradiating a pilot laser Beam, in particular irradiation in a current processing position or in a Be rich around a current point of impact of a (processing) laser beam. The reflected radiation or the pilot laser beam or the LED light can have any wavelength, in particular a wavelength in the infrared range or in the visible green or blue range. In particular, an LED light source or a pilot laser beam source can have a wavelength of approximately 630 nm or approximately 530 nm, for example. At least part of a beam path of an LED light or pilot laser beam radiated into a processing area preferably runs coaxially to the beam path of a processing laser beam.

The method according to the invention therefore makes it possible to identify whether there is a gap between the connected workpieces. The method according to the invention also makes it possible to identify whether a welded connection exists. The welded connection can refer to an electrical and / or mechanical (i.e. physical) welded connection, i.e. there is an electrical or mechanical contact between the workpieces. A welded connection exists when there is no gap between the connected workpieces (so-called zero gap), or when there is a gap, but it is bridged (gap with gap bridging). There is no weld connection if a gap is not bridged. Accordingly, the method can be used to analyze a welded electrical connection, in particular to detect a lack of electrical contact between connected workpieces, e.g. when connecting battery cells to battery modules. Thus, according to the invention, a distinction can be made between good welds or welds without a gap from welds with a gap and a distinction between welds with a gap and those with gap bridging and those without gap bridging.

It is also possible to classify the weld as: (i) a proper welded connection, ie a welded connection without a gap, also referred to as a “good weld” or a “weld with a zero gap”, (ii) a weld with a gap and with a gap bridging, so that there is (electrical or mechanical) contact between the connected workpieces, and (iii) a weld with a gap but without bridging a gap, so that there is no (electrical or mechanical) contact between the connected workpieces. The classification is preferably carried out during laser welding, i.e. during the laser welding process for producing the weld.

The workpieces connected by the laser welding are preferably assessed or marked as “good” or “good part” if it is determined that a weld connection exists, and assessed or marked as “bad” or “bad part” if determined becomes that there is no welded connection. Based on this, the laser welding can also be regulated or controlled. For example, processing parameters such as the laser power supplied, the distance between a laser processing device and the workpieces, a focus position and / or focus position of a laser beam used for laser welding, etc., can be adjusted or regulated, especially in real time. The method can further comprise outputting an error for workpieces if it is determined that there is no welded joint and / or outputting a warning for workpieces if it is determined that a gap, in particular a gap with a gap width greater than a predetermined one Value.

In one embodiment, the determination based on the second measurement signal as to whether there is a welded connection or a gap bridging can only take place if it was previously determined that a gap is present.

At least one step of the method according to the invention can be carried out during the laser welding of the weld, in particular in real time. Accordingly, the method according to the invention can be referred to as an “in-line method”. The first and / or second measurement signal are preferably recorded during the laser welding. Likewise, determining whether there is a gap and / or determining whether a welded connection or a gap bridging exists can take place during the laser welding. The entire method according to the invention is preferably carried out during the laser welding.

The method according to the invention can be used in particular for laser welding with an overlap or parallel joint.

The first measurement signal and / or the second measurement signal can be based on a measurement of a radiation intensity. In particular, the first measurement signal can be based on a measurement of a radiation intensity of the process radiation, and / or the second measurement signal can be based on a measurement of a radiation intensity of the reflected radiation, e.g. the reflected laser radiation. The process radiation generated during laser welding can be temperature radiation in the infrared wavelength range of light and / or plasma radiation in the visible range of light.

The first measurement signal can be recorded in a first wavelength range above the wavelength of a laser beam used for laser welding and / or above the wavelength of the reflected radiation. Alternatively or additionally, the first measurement signal can be used in a second wavelength range below the wavelength of a th laser beam and / or below the wavelength of the reflected radiation. The first wavelength range can correspond to an infrared wavelength range of the light. In other words, the first measurement signal can correspond to temperature radiation in the first wavelength range. The second wavelength range can correspond to a visible wavelength range of light. In other words, the first measurement signal in the second wavelength range can correspond to a plasma radiation. The first measurement signal in the first wavelength range can be detected by at least one first photodiode with spectral sensitivity in the first wavelength range. The first measurement signal in the second wavelength range can be detected by at least one second photodiode with spectral sensitivity in the second wavelength range. In other words, the first measurement signal is preferably separated in the first wavelength range and in the second wavelength range or is detected by at least one photodiode in each case.

The second measurement signal or the reflected radiation, in particular the reflected laser radiation, or the laser beam used for laser welding or the irradiated pilot laser beam or the irradiated LED light can be in the infrared, blue or green wavelength range or spectral range. In other words, an infrared laser beam source can be used as the beam source for the (machining) laser beam or for the pilot laser beam. Alternatively, a laser beam source can emit the laser beam used for laser welding or the pilot laser beam in the green or blue spectral or wavelength range.

The first measurement signal can therefore be based on a detection of the radiation intensity of the process radiation in a first wavelength range, in particular in an infrared range, in order to detect temperature radiation, and / or based on a detection of the radiation intensity of the process radiation in a second wavelength range, in particular in a visible area in order to detect plasma radiation. The first measurement signal recorded in the first wavelength range can accordingly be referred to as a “temperature signal”. The first measurement signal recorded in the second wavelength range can accordingly be referred to as a “plasma signal”.

The process radiation generated during laser welding can be detected by at least one (first and / or second) photodiode as the first measurement signal and / or the reflected radiation can be detected by at least one (third) photodiode as the second measurement signal. The third photodiode can have a spectral sensitivity in the wavelength range of the laser used for laser welding. In other words, the first and the second measurement signal are preferably separated or by at least each detected by a photodiode. The photodiodes preferably have different spectral sensitivities from one another.

Determining whether there is a gap between the workpieces can include determining a gap width based on the first measurement signal. In this case, it can be determined that there is a gap if the gap width is greater than a predetermined gap width limit value. The gap width limit value can be between 50 pm and 200 pm, in particular 100 pm and 175 pm, or be 50 pm, 100 pm or 150 pm.

The gap width can for example be defined as the shortest distance between the connected workpieces adjacent to but outside the weld or a weld seam. For example, the gap width, for example in the case of a lap joint or parallel joint, can be defined as the shortest distance between the oppositely arranged workpiece surfaces.

Determining whether there is a gap between the workpieces can include determining whether the first measurement signal is below a reference value or a reference curve. If the first measurement signal is recorded for the first wavelength range and the second wavelength range, it can be determined whether the first measurement signal of the first wavelength range is below a first reference value or reference curve and whether the first measurement signal of the second wavelength range is below a second reference value or Reference curve is located. The reference curve can be a lower envelope curve. In this case, it can be determined that there is a gap between the workpieces if the measurement signal is below the reference value or the reference curve. Determining whether there is a gap between the workpieces can also include determining whether the first measurement signal falls below a reference value or a reference curve. In this case, it can be determined that there is a gap between the workpieces if the measurement signal falls below the reference value or the reference curve.

Determining whether there is a gap between the workpieces can include forming a first integral over the first measurement signal. In this case, it can be determined that there is a gap between the workpieces when the first integral falls below a predetermined first integral limit value. The first integral can be formed over at least one area of the first measurement signal.

As an alternative or in addition, determining whether there is a gap between the workpieces can include forming a first mean value using the first measurement signal. In this case it can be determined that there is a gap between the workpieces when the first mean value falls below a predetermined first mean value limit value. The first mean value can be formed over at least one range of the first measurement signal.

Alternatively or additionally, determining whether there is a gap between the workpieces can include determining a first outlier frequency of the first measurement signal. In this case, it can be determined that there is a gap between the workpieces if the first outlier frequency of the first measurement signal exceeds a predetermined first outlier limit value. The first outlier frequency can be formed over at least one area of the first measurement signal.

If the first measurement signal is recorded for the first wavelength range and the second wavelength range, the determination of whether there is a gap between the workpieces, the formation of a first integral over the first measurement signal recorded in the first wavelength range, ie the temperature signal, and the Forming a second integral over the first measurement signal recorded in the second wavelength range, ie the plasma signal, it being determined that there is a gap between the workpieces when the first integral falls below a predetermined first integral limit value and / or when the second Integral falls below a predetermined second integral limit value.

If the first measurement signal is recorded for the first wavelength range and the second wavelength range, the determination of whether there is a gap between the workpieces, the formation of a first mean value over the first measurement signal recorded in the first wavelength range, ie the temperature signal, and the Forming a second mean value over the first measurement signal recorded in the second wavelength range, ie the plasma signal, it being determined that there is a gap between the workpieces if the first mean value falls below a predetermined first mean value limit value and / or if the second mean value falls below a predetermined second mean value limit value.

If the first measurement signal is recorded for the first wavelength range and the second wavelength range, the determination of whether there is a gap between the workpieces, the determination of a first outlier frequency of the first measurement signal recorded in the first wavelength range, ie the temperature signal, and that Calculate a second outlier frequency of the first measurement signal detected in the second wavelength range, ie the plasma signal. In this case, it can be determined that there is a gap between the work pieces if the first outlier frequency exceeds a predetermined first outlier value. Exceeds the limit value and / or if the second outlier frequency exceeds a predetermined second outlier limit value.

The outlier frequency can be defined as a frequency or number of values of the first measurement signal that lie outside of predetermined envelope curves for the first measurement signal. The outlier frequency can be specified as a percentage in relation to a considered and / or predefined time interval or measurement interval or to an observed and / or predefined range of the first measurement signal. Alternatively, the outlier frequency can be given in absolute terms. If the first measurement signal is detected in the first and in the second wavelength range, the first outlier frequency, based on a frequency or number of values of the first measurement signal in the first wavelength range, which lie outside of predetermined first envelope curves for the first measurement signal, and the second Outlier frequency can be determined based on a frequency or number of values of the first measurement signal in the second wavelength range that lie outside of predefined second envelope curves for the first measurement signal.

The determination of whether a welded connection or a gap bridging exists can be determined based on a noise of the second measurement signal. The noise can be determined as the deviation from a mean value of the second measurement signal, e.g. in a specified time interval or measurement interval or in a considered and / or specified range of the second measurement signal, and optionally provided with a gain factor. The noise can also be referred to as the “noise signal” or the “noise component” of the second measurement signal.

It can be determined that there is no welded connection or a gap bridging if an outlier frequency of the noise of the second measurement signal exceeds a specified first noise threshold value, and / or if an integral over the noise of the second measurement signal exceeds a specified second noise threshold value exceeds.

The outlier frequency of the noise of the second measurement signal can be defined as a frequency or number of values of the noise that lie outside predetermined envelope curves and / or predetermined tolerance ranges for the noise. The outlier frequency can be specified as a percentage in relation to a considered time interval and / or measurement interval or to an area of the second measurement signal. Alternatively, the outlier frequency can be given in absolute terms. At least one of the workpieces can have or consist of aluminum and / or copper and / or nickel. In particular, one of the workpieces can be made of aluminum and another of the workpieces can comprise copper, the latter optionally being able to be coated with nickel (layer thickness, for example, 8 μm). The coating can be applied by electroplating.

At least one of the workpieces can have a thickness of 0.10 mm to 0.50 mm, preferably a thickness of 0.15 mm to 0.35 mm, particularly preferably a thickness of 0.20 mm to 0.30 mm.

The workpieces can be or comprise a sheet metal or an arrester. One of the workpieces can comprise a battery, a battery module and / or a battery cell, and / or another of the workpieces can comprise an arrester. A welded electrical contact between the arrester and the battery cell can be analyzed as a weld.

According to a further aspect of the present disclosure, a method for laser welding a first workpiece and a second workpiece is specified, comprising the steps of: arranging the workpieces such that a first surface of the first workpiece and a first surface of the second workpiece lie on top of one another or with one another are in contact; Laser welding of the workpieces to form a welded connection between the workpieces by irradiating a laser beam onto a second surface of the first workpiece, the second surface of the first workpiece being opposite the first surface of the first workpiece and / or by irradiating a laser beam onto a second upper surface of the second workpiece, the second surface of the second workpiece facing the first surface of the second workpiece; and performing the method for analyzing the weld joint according to one of the preceding claims.

The first surface and the second surface of the first workpiece and / or the first surface and the second surface of the second workpiece can be formed parallel to one another. The first workpiece and / or the second workpiece can be designed as a sheet metal or a conductor or comprise a metal sheet or a conductor. The first and second surfaces of the work pieces can be referred to as the main surfaces of the work pieces.

The first surfaces of the workpieces can touch in at least one area. In a further area, there can be a gap between the workpieces. The workpieces can be arranged with the aim of ensuring that the gap between the workpieces does not exist or is as small as possible. The workpieces can be arranged in an overlap joint or parallel joint.

The methods according to the invention can be carried out by a laser processing system which comprises a laser processing device for processing a workpiece by means of a laser beam, in particular a laser welding head, and a sensor module. The laser processing device can have a beam splitter for decoupling process radiation from the beam path of the laser beam. The laser processing device can comprise an optical output for coupling out process radiation and the sensor module can comprise an optical input for coupling in the process radiation emerging from the laser processing device. The sensor module comprises at least one detector for detecting the process radiation and for detecting the reflected radiation, in this example the reflected laser radiation of the (processing) laser beam. In one embodiment, the laser processing system can include an LED lighting unit for irradiating LED light. In this case, the reflected radiation detected by the sensor module comprises reflected LED radiation or reflected LED light. In a further embodiment, the laser processing system can comprise a pilot laser unit for irradiating a pilot laser beam. In this case, the reflected radiation detected by the sensor module comprises reflected pilot laser radiation or reflected LED light. The pilot laser unit can comprise a pilot laser beam source. The laser processing system can comprise a pilot laser beam source, for example for generating a pilot laser beam with a wavelength of approximately 630 nm or approximately 530 nm. Alternatively or additionally, the laser processing system can comprise an LED source for generating LED light. The LED light can be coupled into a beam path of the machining laser beam or into the laser machining device, for example by means of a beam splitter. The sensor module can be coupled to the laser processing device. The at least one detector can be set up to detect at least one beam parameter of the process radiation, in particular an intensity in a specific wavelength range. The at least one detector can also be set up to output a measurement signal based on the detection. The detectors can comprise a photodiode and / or a photodiode array and / or a camera, for example a CMOS- or CCD-based camera. The sensor module can comprise a plurality of detectors which are each set up to detect the process radiation at different wavelengths or in different wavelength ranges. The laser processing system can further comprise a control unit. The control unit can be set up to receive analog measurement signals from the at least one detector. The control unit can be set up a method perform according to one of the embodiments listed in this disclosure to analyze welded joints. The control unit can also be set up to regulate or control the laser processing system, in particular the laser processing device, based on a result of the analysis, as described above.

The respective detectors can only be sensitive at a certain wavelength or in a certain wavelength range. For example, a first detector can be sensitive in the visible range of light, a second detector can be sensitive in an infrared range, and / or a third detector can be sensitive in a laser emission wavelength range of the laser processing device. The detectors can therefore be designed in such a way that they are sensitive in different wavelength ranges. According to one embodiment, the sensor module comprises a first detector with a photodiode that is sensitive in the visible spectrum of light to detect plasma process emissions or plasma radiation, a second detector with a photodiode that is sensitive in the infrared wavelength range to detect temperature To detect process emissions or thermal radiation, and a third detector with a photodiode that is sensitive in the laser emission wavelength range to detect back reflections from the laser of the laser processing device. Accordingly, the method according to the invention can be carried out with the laser processing system. In particular, the described sensor module can detect the first measurement signal, in particular the temperature signal and / or the plasma signal, and the second measurement signal.

According to the present disclosure, a method for the detection of gaps and in particular for differentiating between gaps with connection or with contact and gaps without connection or without contact, in particular with the aid of sensors such as photodiodes, is specified.

Brief description of the drawings

The invention is described in detail below with reference to figures.

1 shows a schematic illustration of a laser processing system for processing a workpiece by means of a laser beam for performing a method for analyzing a welded joint according to embodiments of the present disclosure;

FIG. 2 shows a detailed schematic representation of a sensor module of the laser processing system shown in FIG. 1; 3 shows a flow diagram of a method for analyzing a weld joint during laser welding in accordance with embodiments of the present disclosure;

4A-4D show weld joints analyzed using a method for analyzing a weld joint in laser welding of workpieces in accordance with embodiments of the present disclosure;

FIGS. 5A-5D show, by way of example, temporal progressions of measurement signals that were recorded by a method for analyzing a welded joint during laser welding of workpieces according to embodiments; and

6 shows, by way of example, a determination of gap widths by a method for analyzing a welded joint during laser welding of workpieces according to embodiments of the present disclosure.

Detailed description of the drawings

Unless otherwise noted, the same reference symbols are used below for identical and identically acting elements.

1 shows a schematic illustration of a laser processing system for processing a workpiece by means of a (processing) laser beam according to embodiments of the present disclosure. FIG. 2 shows a detailed schematic illustration of the sensor module of the laser processing system shown in FIG. 1.

The laser processing system 1 comprises a laser processing device 10, a sensor module 20 and a control unit 40.

The laser processing device 10, which can be designed, for example, as a laser processing head, in particular as a laser welding head, is designed to generate a (processing) laser beam (not shown) exiting from a laser light source or one end of a laser guide fiber with the aid of beam guidance and focusing optics (not shown) to focus or bundle on the work piece 30a, 30b to be machined, in order thereby to carry out a machining or a machining process. The processing can in particular include laser welding. During processing, process radiation 11 is produced, which enters the laser processing device 10 and is there out of the beam path of the laser beam by a beam splitter 12. is coupled. The process radiation is directed into the sensor module 20 and there strikes at least one detector D1, D2, D3.

For machining, the workpieces 30a, 30b can be arranged in such a way that they overlap. The workpieces 30a, 30b can be arranged in particular in a parallel joint or lap joint.

For example, as in FIG. 1, a lower surface of the workpiece 30a is opposed to an upper surface of the workpiece 30b, and the laser beam is irradiated onto an upper surface of the workpiece 30a. The upper surfaces and the lower surfaces of the workpieces 30a, 30b can also be referred to as main surfaces or main surfaces of the workpieces 30a, 30b.

As shown, the laser beam is irradiated onto the upper surface or the upper main surface of the workpiece 30a, preferably essentially perpendicular to the main surfaces of the workpieces 30a, 30b. The laser beam is accordingly not radiated onto the edges or edges or parallel to the main surfaces of the workpieces 30a, 30b.

Accordingly, the resulting process radiation 11 is emitted from the upper surface or from the upper main surface of the workpiece 30a. The process radiation 11 is thus preferably detected from the upper surface of the workpiece 30a. Likewise, a reflected radiation is detected preferably from the upper surface of the workpiece 30a. In an exemplary embodiment not shown, the laser processing system can comprise an LED lighting unit for irradiating LED light into a processing area on the workpiece. In this case, the reflected radiation detected by the sensor module comprises reflected LED radiation or reflected LED light. In a further exemplary embodiment, not shown, the laser processing system can comprise a pilot laser unit for irradiating a pilot laser beam into a processing area on the workpiece. In this case, the reflected radiation detected by the sensor module comprises reflected pilot laser radiation or reflected LED light. The pilot laser unit can comprise a pilot laser beam source.

In particular, for laser welding of workpieces 30a, 30b, the arrangement of the workpieces 30a, 30b in the overlap or parallel joint should be such that there is no gap between the workpieces 30a, 30b so arranged, or that the gap is as small as possible. As shown, there is an (undesired) gap between the workpieces 30a, 30b, ie between the upper surface of the workpiece 30b and the lower surface of the workpiece 30a. act. In a plan view of the workpieces 30a, 30b, in particular in a plan view of the upper surface of the workpiece 30a or a plan view of the lower surface of the workpiece 30b, it cannot be recognized whether there is a gap between the workpieces 30a, 30b.

As shown in FIG. 2, the sensor module 20 preferably comprises a plurality of detectors or sensors D1, D2, D3 which are set up to detect various parameters, such as an intensity, of the process radiation 11 and to output a measurement signal based thereon. Each of the detectors D1, D2, D3 can comprise a photodiode or a photodiode or pixel array. The detectors preferably comprise a photodiode or a sensor for the visible spectral range, a photodiode or a sensor for the infrared spectral range and a photodiode or a sensor for a wavelength range of the laser beam or the irradiated pilot laser beam or the irradiated LED light. Furthermore, the sensor module 20 can comprise a plurality of beam splitters 221, 222 in order to split up the process radiation 11 and direct it onto the corresponding detectors D1, D2, D3. The beam splitters 221, 222 can be designed as partially transparent mirrors and, according to embodiments, can be wavelength-selective.

The control unit 40 is connected to the sensor module 20 and receives the measurement signals from the detectors D1, D2, D3. The control unit 40 can be set up to record the measurement signals from the detectors D1, D2, D3. The control unit 40 is set up to determine and / or analyze a machining result of the laser machining, and is set up in particular to analyze welded connections. The control unit 40 can further be set up to control the laser processing device 10 based on a result of the analysis.

The laser processing system 1 can be set up to carry out laser processing processes, in particular special laser welding, and to carry out methods for analyzing a weld connection during laser welding of workpieces according to embodiments of the present disclosure.

FIG. 3 shows a flow chart of a method for analyzing a welded connection during laser welding of workpieces according to embodiments of the present disclosure.

The method begins with the acquisition of a first measurement signal for a process radiation generated during laser welding (step S1). The method further includes detecting a second Measurement signal for a radiation reflected from the workpieces (step S2). The acquisition of the first measurement signal and the acquisition of the second measurement signal can take place simultaneously according to embodiments. Then, based on the first measurement signal, it is determined whether there is a gap between the workpieces (step S3). If it is determined that there is a gap, it is determined on the basis of the second measurement signal whether there is or is a welded connection or a gap bridging between the two workpieces (step S4). In other words, it is determined whether there is electrical or mechanical contact between the workpieces.

The method therefore makes it possible to identify whether there is a gap between the connected workpieces. The method also makes it possible to identify whether there is a gap bridging, i.e. a welded connection, in particular an electrical and mechanical welded connection. In particular, the method can be used to analyze a welded electrical connection, for example to detect a lack of electrical contact between connected workpieces. Accordingly, it is possible to distinguish whether a proper weld, ie a weld without a gap, also known as a "good weld" or as a "weld with an O-gap", or whether a weld with a gap and with gap bridging, so that a There is electrical contact between the connected workpieces, or a weld with a gap but without a gap bridging, so that there is no electrical contact between the connected workpieces.

The first measurement signal is preferably recorded in two different wavelength ranges. For example, the first measurement signal can be based on a detection of the radiation intensity of the process radiation in a first wavelength range above the wavelength of the reflected radiation or above the wavelength of the laser beam used for laser welding, in particular in an infrared range, and on a detection of the radiation intensity of the process radiation in one second wavelength range below the wavelength of the reflected radiation or below the wavelength of the laser beam, in particular in a visible range. The first measurement signal recorded in the first wavelength range can correspond to temperature radiation and can be referred to as a “temperature signal”. The first measurement signal recorded in the second wavelength range can correspond to a plasma radiation and can be referred to as a “plasma signal”. However, it is also possible to record or evaluate only the first measurement signal in only one of these wavelength ranges. As mentioned above, the reflected radiation can comprise reflected laser radiation from an irradiated pilot laser beam or reflected laser radiation from the (machining) laser beam used for the welding process or reflected laser radiation from an irradiated LED light. In the embodiment of Figures 1 and 2, the plasma signal can be detected by the detector Dl, which is sensitive in a wavelength range below the wavelength of the reflected radiation or the laser beam, in particular in the visible wavelength range of light, in order to measure the intensity of plasma Detect process emissions. The temperature signal can be detected by the detector D2, which is sensitive in a wavelength range above the wavelength of the reflected radiation or the laser beam, in particular in an infrared wavelength range of the light, in order to determine the intensity of process emissions in the infrared or temperature range. Spectral range, ie of temperature radiation, to be detected. The second measurement signal can be detected by the detector D3, which is sensitive in the wavelength range of the reflected radiation or the laser beam in order to detect back reflections from the laser of the laser processing device.

According to embodiments, determining whether there is a gap between the workpieces (step S3) can include forming a first integral over the plasma signal and forming a second integral over the temperature signal. In this case, it can be determined that there is a gap between the workpieces when the first integral falls below a predetermined first integral limit value and / or when the second integral falls below a predetermined second integral limit value.

According to embodiments, the determination of whether a welded connection or a gap is bridged (step S4) can take place on the basis of a noise in the second measurement signal of the noise of the second measurement signal exceeds a predetermined first noise limit value, and / or if an integral over the noise of the second measurement signal exceeds a predetermined second noise limit value. The noise can be defined as a deviation from a mean value of the second measurement signal, preferably in a predetermined time interval or measurement signal, and in particular amplified by a predetermined factor. The mean value can be specified or determined based on the second measurement signal.

According to embodiments, at least one of steps S1 to S4 can take place during the laser welding of the welded connection.

One of the workpieces preferably comprises a battery, a battery module and / or a battery cell and another of the workpieces comprises an arrester. In this case, the method according to embodiments of the present disclosure for analyzing a ge welded electrical contact between the arrester and the battery, the battery module or the battery cell can be used. In particular, one of the workpieces can consist of aluminum and another of the workpieces can comprise copper and be coated with nickel. The coating can be applied by electroplating. At least one of the workpieces can have a thickness of 0.10 mm to 0.50 mm, preferably a thickness of 0.15 mm to 0.35 mm, particularly preferably a thickness of 0.20 mm to 0.30 mm.

In one embodiment, arresters of two or more batteries are welded or contacted with one another. The arresters can be made of copper Cu or aluminum Al. In particular, an arrester of a first battery can be made of aluminum or copper and an arrester of a second battery can be made of aluminum or copper, so that the weld connection between aluminum and aluminum Al-Al, or between copper and copper Cu-Cu or between aluminum and Copper Al-Cu is formed.

The laser welding can comprise the gas-tight welding of cell housings of battery cells, the welding of membranes of cell covers of battery cells, the welding of connections in the cell covers of battery cells and the welding of a rupture plate of cell covers of battery cells.

The method according to embodiments of the present disclosure can be used, in particular, for analyzing a welded joint when laser welding workpieces in an overlap or parallel joint, and in particular in the case of I-welded seams.

4A-4D show weld joints analyzed using a method for analyzing a weld joint during laser welding of workpieces in accordance with embodiments of the present disclosure.

4A-4D each show in the top line (“camera”) a top view of I-welds created during laser welding in the lap joint and each show a sectional view of the respective weld in the middle line. In the lower line, a schematic view of the sectional view is shown in each case. In the top view of the respective workpieces 30a, 30b or the respective weld seams, it is not possible to distinguish whether a weld without a gap, a weld with a gap and gap bridging, or a weld with a gap but without a gap bridging is present. The top view is of the upper surface of the workpiece 30a, as was explained with reference to FIG. 1. In the first column (“Gap: 0 pm”), FIG. 4A shows a proper weld seam, also referred to as a “good weld”, which was recognized with the aid of the method for analyzing welded joints during laser welding of workpieces according to embodiments of the present disclosure. The welded workpieces 30a, 30b, shown here as metal sheets, have no gap between them and current can flow via the weld seam. The resulting weld joint is marked as a "good weld" or with a "0 gap".

4B-4D show typical defect patterns that were detected with the aid of the method for analyzing welded joints during laser welding of workpieces according to embodiments of the present disclosure.

In the second column (“Gap: 100 pm”), FIG. 4B shows a gap S between the two welded workpieces 30a, 30b. This gap S can be tolerated because the gap S is bridged (gap bridging “B” in Fig. 4B). Thus, despite the existing gap S, there is still electrical contact between the welded workpieces, i.e. there is a welded connection. This is also referred to as “weld with gap bridging” or “gap with (electrical) connection or (electrical) contact”.

4C and 4B show in the third and fourth columns (“Gap: 150 pm” and “Gap: 200 pm”) another typical error pattern, also referred to as “false friend” or “false friend”. There is a gap S between the welded workpieces 30a, 30b, which is not bridged, so that there is no electrical contact between the workpieces. This is also referred to as “weld without bridging gap” “gap without (electrical) connection or (electrical) contact”. So there is no welded connection.

5A to 5D show, by way of example, temporal profiles of measurement signals that were recorded by a method for analyzing a welded joint during laser welding of workpieces according to embodiments.

In the embodiment shown in FIGS. 5A to 5D, the first measurement signal was recorded in the first and second wavelength ranges and comprises the plasma signal PI and the temperature signal P2. The second measurement signal for the reflected laser light is referred to as the back-reflection signal P3. FIGS. 5A-5D show exemplary courses of the measurement signals PI, P2 and P3 each for a laser welding process. In addition, the course of a noise of the measurement signal P3 is shown as “P3 noise”. The method according to embodiments of the present disclosure includes acquiring the plasma signal PI and the temperature signal P2. It is determined that there is a gap between the workpieces if, for example, the plasma signal PI and / or the temperature signal P2 falls, ie lies on a respective lower envelope curve or lies below or falls below it. This can be determined, for example, by forming a first integral over the plasma signal PI and a second integral over the temperature signal P2. If the first integral falls below a predefined first integral limit value and / or if the second integral falls below a predefined second integral limit value, there is a gap. If there is a gap, it is determined based on the reflex signal P3 whether a weld connection or a gap bridging exists. There is no welded joint or gap bridging if an outlier frequency of the noise of the back-reflection signal P3 exceeds a predetermined first noise limit value, and / or if an integral over the noise of the back-reflection signal P3 exceeds a predetermined second noise limit value. Otherwise there is a gap with gap bridging, ie a welded connection.

With the method, on the one hand, good welds, i.e. welds without a gap between the workpieces, can be distinguished from welds with a gap. On the other hand, welds with a gap but with gap bridging can be distinguished from welds with a gap but without gap bridging.

In FIG. 5A, the integrals of the plasma signal PI and of the temperature signal P2 exceed the respective limit values. The weld produced during the laser welding process is marked as a "good weld". A welding connection with an O-gap is present between the workpieces connected in this way. In particular, there is an electrical contact or an electrical connection between the connected workpieces. This corresponds to the weld connection shown in FIG. 4A.

In Fig. 5B-5D, the plasma signal PI and the temperature signal P2 have fallen compared to the respective given reference values or envelope curves. In other words, the integrals of the plasma signal PI and the temperature signal P2 fall below the respective limit values. The welds produced during the respective laser welding process are identified as welds with a gap.

According to embodiments, it is sufficient if either the integral of the plasma signal PI or the integral of the temperature signal P2 falls below the respective limit value. According to In further embodiments, it can be determined that a gap is only present if both the integral of the plasma signal PI and the integral of the temperature signal P2 fall below the respective limit value.

In FIG. 5B there is a gap with a 100 μm gap width between the workpieces, in FIG. 5C there is a gap with a 150 μm gap width between the workpieces and in FIG. 5D there is a gap with a 200 μm gap width between the workpieces. The welds shown in FIGS. 5B-5D correspond to the welds shown in FIGS. 4B-4D. The gap width can be determined based on the integral value of the plasma signal PI and / or the temperature signal P2. If the integral value lies in a first range, the corresponding weld can be assigned a gap width of a first value or value range. Correspondingly, a gap width of a second value or value range can be assigned to an integral value which lies in a second range, etc. This is illustrated by way of example in FIG. 6 for the plasma signal PI.

For the corresponding welds in FIGS. 5B-5D, it is now determined whether a welded connection is still present between the workpieces and, accordingly, an electrical contact or an electrical connection. For this purpose, the noise of the back reflex signal P3, P3 noise, is analyzed.

In FIG. 5B, an outlier frequency of the noise of the back reflex signal P3 is below a predetermined first noise limit value. It is therefore determined that, despite the existing gap, there is a welded connection between the workpieces or a gap bridging.

In FIGS. 5C and 5D, an outlier frequency of the noise of the back reflex signal P3 is above the predetermined first noise limit value. It is therefore determined that there is no weld connection or gap bridging, and thus no electrical contact, between the workpieces.

The present invention is based on the knowledge that in the case of laser welding in the overlap joint, a good weld can be distinguished from welds with a gap in that the intensity of a plasma signal and the intensity of a temperature signal of the laser welding process decrease. Furthermore, the present invention is based on the knowledge that a weld with a gap and with gap bridging can be distinguished from a weld with a gap but without gap bridging in that in the latter case the noise of a back-reflection signal of the radiation reflected back by the workpieces is significant. kant increases. Accordingly, a combination of the plasma signal and the temperature signal with the back-reflection signal provides unambiguous information about the presence or absence of a welded connection, in particular an electrical contact, between the workpieces. Here, “there is a gap” can be viewed as a necessary condition, and excessive noise as a sufficient condition for the gap not to be bridged. This means that it can be clearly identified whether there is a wrong friend.

Claims

Expectations

A method for analyzing a weld joint during laser welding of workpieces (30a, 30b), comprising:

Detecting (Sl) a first measurement signal (PI, P2) for a process radiation generated during laser welding;

Detecting (S2) a second measurement signal (P3) for a radiation reflected from the workpieces (30a, 30b);

Determining (S3) based on the first measurement signal (PI, P2) whether there is a gap (S) between the workpieces (30a, 30b); and if it is determined that there is a gap (S), determining (S4) based on the second measurement signal (P3) whether there is a welded joint.

2. The method according to claim 1, wherein the reflected radiation comprises at least one of the fol lowing: reflected laser radiation of the machining laser beam, reflected radiation of irradiated LED light in a machining area and reflected laser radiation of a pilot laser beam irradiated in a machining area.

3. The method according to claim 1 or 2, wherein the first measurement signal (PI, P2) and / or second measurement signal (P3) is based on a detection of a radiation intensity.

4. The method according to any one of the preceding claims, wherein the first measurement signal (PI, P2) is detected in a first wavelength range above the wavelength of a processing laser beam used for laser welding and / or above the wavelength of the reflected radiation, and / or wherein the first Measurement signal (PI, P2) is detected in a second wavelength range below the wavelength of a machining laser beam used for laser welding and / or below the wavelength of the reflected radiation.

5. The method according to any one of the preceding claims, wherein the process radiation detected as the first measurement signal (PI, P2) is temperature radiation in the infrared spectral range and / or plasma radiation in the visible spectral range.

6. The method according to any one of the preceding claims, wherein the reflected radiation detected as the second measurement signal (P3) is in the infrared spectral range or in the visible green or blue spectral range.

7. The method according to any one of the preceding claims, wherein determining (S3) whether there is a gap (S) between the workpieces (30a, 30b) comprises determining a gap width based on the first measurement signal (PI, P2), and wherein it is determined that a gap (S) is present if the gap width is greater than a given gap width limit value.

8. The method according to any one of the preceding claims, wherein determining (S3) whether there is a gap (S) between the workpieces (30a, 30b) comprises determining whether the first measurement signal (PI, P2) is below a reference value or a Reference curve lies or falls below it, whereby it is determined that a gap (S) is present between the workpieces (30a, 30b) if the measurement signal (PI, P2) is below the reference value or the reference curve or falls below it.

9. The method according to any one of the preceding claims, wherein determining (S3) whether there is a gap (S) between the workpieces (30a, 30b), the formation of a first integral over the first measurement signal (PI, P2) and / or one first mean value of the first measurement signal (PI, P2), it being determined that there is a gap (S) between the workpieces (30a, 30b) if the first integral falls below a predetermined first integral limit value and / or if the first mean value falls below a predetermined first mean value limit value.

10. The method according to any one of the preceding claims, wherein the first measurement signal (PI, P2) in a first wavelength range above the wavelength of the reflected radiation or above the wavelength of a processing laser beam used for laser welding and in a second wavelength range below the wavelength of the reflected radiation or below the wavelength of the machining laser beam used for laser welding is detected, and determining (S3) whether there is a gap (S) between the workpieces (30a, 30b), forming a first integral over the first measurement signal (PI) detected in the first wavelength range and comprises forming a second integral over the first measurement signal (P2) detected in the second wavelength range, and wherein it is determined that a gap (S) is present between the workpieces (30a, 30b) when the first integral has a predetermined first integral limit value falls below and / or if the second integral a vorg falls below the specified second integral limit value.

11. The method according to any one of the preceding claims, wherein based on a noise rule of the second measurement signal (P3) it is determined whether a welded connection exists.

12. The method according to claim 11, wherein it is determined that there is no weld joint if an outlier frequency of the noise of the second measurement signal (P3) exceeds a predetermined first noise limit value, and / or if an integral over the noise of the second measurement signal ( P3) exceeds a predetermined second noise limit value.

13. The method according to any one of the preceding claims, wherein at least one of the work pieces (30a, 30b) comprises aluminum and / or copper and / or nickel or is therefrom.

14. The method according to any one of the preceding claims, wherein at least one of the work pieces has a thickness of 0.10 mm to 0.50 mm, preferably a thickness of 0.15 mm to 0.35 mm, particularly preferably a thickness of 0.20 mm to 0.30 mm.

15. The method according to any one of the preceding claims, wherein the workpieces (30a, 30b) comprise an arrester of a first battery and an arrester of a second battery, and wherein a welded electrical contact between the conductors of the batteries is analyzed as a welded connection.

16. The method according to any one of the preceding claims, wherein the workpieces are arranged in the laser welding in a lap joint or parallel joint.

17. A method for laser welding a first workpiece (30a) and a second workpiece (30b), comprising the steps:

Arranging the workpieces (30a, 30b) such that a first surface of the first workpiece (30b) and a first surface of the second workpiece (30b) lie on top of one another;

Laser welding of the workpieces (30a, 30b) to form a welded joint between the workpieces (30a, 30b) by irradiating a machining laser beam onto a second surface of the first workpiece (30a), the second surface of the first workpiece (30a) being the first surface the first workpiece (30b) is opposite and / or by irradiating a machining laser beam onto a second surface of the second workpiece (30b), the second surface of the second workpiece (30b) being opposite to the first surface of the second workpiece (30b);

Carrying out the method for analyzing the weld joint according to one of the preceding claims.

18. The method according to claim 17, wherein the workpieces are arranged in a lap joint or parallel joint.

19. The method according to claim 17 or 18, wherein the first surfaces of the work pieces (30a, 30b) touch in at least one area and / or wherein a gap is present in a further area between the first surfaces of the work pieces (30a, 30b) .