WO2025035553A1 - 焊接质量检测方法、装置、计算机可读存储介质和产品 - Google Patents

焊接质量检测方法、装置、计算机可读存储介质和产品 Download PDF

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Publication number
WO2025035553A1
WO2025035553A1 PCT/CN2023/122918 CN2023122918W WO2025035553A1 WO 2025035553 A1 WO2025035553 A1 WO 2025035553A1 CN 2023122918 W CN2023122918 W CN 2023122918W WO 2025035553 A1 WO2025035553 A1 WO 2025035553A1
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Prior art keywords
welding
vibration
sample
frequency
good
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English (en)
French (fr)
Inventor
吴凯
孙龙利
丁宇
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Contemporary Amperex Technology Co Ltd
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Contemporary Amperex Technology Co Ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N19/00—Investigating materials by mechanical methods
    • G01N19/08—Detecting presence of flaws or irregularities
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/02—Details
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/24—Investigating strength properties of solid materials by application of mechanical stress by applying steady shearing forces
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/32—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/0001—Type of application of the stress
    • G01N2203/0005—Repeated or cyclic
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/0014—Type of force applied
    • G01N2203/0025—Shearing
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/02—Details not specific for a particular testing method
    • G01N2203/026—Specifications of the specimen
    • G01N2203/0296—Welds
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/02—Details not specific for a particular testing method
    • G01N2203/06—Indicating or recording means; Sensing means
    • G01N2203/067—Parameter measured for estimating the property
    • G01N2203/0688—Time or frequency

Definitions

  • the present application relates to the field of battery technology, and in particular to a welding quality detection method, a welding quality detection system, a welding quality detection device, a computer-readable storage medium, and a computer program product.
  • the welding quality between the various components of the battery will affect the reliability of the produced battery. If batteries with poor welding quality flow into the market, it may cause product safety risks.
  • the present application aims to solve at least one of the technical problems existing in the background technology.
  • one purpose of the present application is to provide a welding quality detection method and device to improve the detection rate of welding problems in the battery manufacturing process to a certain extent.
  • An embodiment of the first aspect of the present application provides a welding quality detection method, the method comprising: acquiring vibration data of a welding sample detected by a vibration detector at a resonant frequency, wherein the resonant frequency is an excitation frequency at which the welding sample is driven to vibrate via a vibration generator; based on the vibration data, determining at least one vibration parameter of the welding sample; and in response to at least one of the at least one vibration parameter satisfying a standard associated with a corresponding threshold, determining that a welding defect exists in the welding sample.
  • the defect detection is performed by directly extracting the vibration parameters of the welding sample at the resonant frequency, which has the characteristics of high detection accuracy, convenience and efficiency. If the welding part can keep the various vibration parameters stable at the resonant frequency, it means that the welding quality is good. On the contrary, if the various vibration parameters meet the requirements at the resonant frequency, the welding quality is good.
  • the standards associated with the corresponding thresholds indicate that there may be problems at the welding site, which improves the detection rate of welding defects to a certain extent.
  • the threshold value of at least one vibration parameter is obtained by statistically analyzing the values of at least one vibration parameter of at least one good weld at the resonant frequency.
  • the good weld is used to set the inspection standard, and the purpose of setting the threshold value of each vibration parameter is to determine whether the weld sample to be tested is qualified based on the threshold value in subsequent tests.
  • the resonant frequency is obtained by detecting the maximum vibration speed of at least one good weld product.
  • the sample vibration signal can reach a peak value, which helps to reduce the influence of noise in the measurement process on the measurement result, thereby improving the measurement accuracy.
  • At least one good welding product is obtained by the following steps: obtaining the shear force test results of each of M welding samples in N welding samples, wherein the N welding samples are welded under the same process conditions, N and M are integers greater than 1, and M ⁇ N; in response to the shear force test results of each of the M welding samples satisfying the good product evaluation index, determining that the remaining N-M welding samples in the N welding samples are at least one good welding product.
  • the welding difference between the same batch of welding samples welded under the same process conditions is small, so by selecting a part of the same batch of welding samples welded under the same process conditions for shear force testing, when the shear force test results of each welding sample meet the good product evaluation index, it is considered that the welding samples of the batch meet the requirements of good welding products, and the remaining N-M welding samples that have not been subjected to shear force testing can be determined as good welding products.
  • the shear force test result includes the weld mark residual rate of the welding sample under shear force, wherein the weld mark residual rate is the ratio of the number of residual weld points of the welding sample after stretching under shear force to the total number of weld points of the welding sample.
  • the good product evaluation index includes: 100 Newtons (N) ⁇ ⁇ ⁇ 800N, ⁇ is the shear force borne by the good welding product; 0.5 ⁇ R ⁇ 1, R is the weld mark residual rate of the good welding product.
  • the shear force and weld mark residual rate can be used to characterize the shear strength and welding quality in the welding structure, to evaluate the actual performance of the welding quality, and to better evaluate the welding quality of the battery tab and the adapter.
  • the at least one vibration parameter includes at least one of a characteristic parameter characterizing a vibration shape of the welding sample, a vibration velocity of the welding sample, and a soldering rate of a weld print zone of the welding sample, wherein the soldering rate is a ratio of an area of a soldering region within the weld print zone to an area of the weld print zone.
  • the detection accuracy and efficiency of the welding joint can be improved to a certain extent.
  • the characteristic parameter of the vibration shape includes the aspect ratio of the vibration shape.
  • the corresponding threshold includes a first threshold for the aspect ratio of the vibration shape, and the standard associated with the first threshold is that the aspect ratio of the vibration shape is less than the first threshold.
  • the corresponding threshold value includes a second threshold value for the vibration speed of the welding sample, and the standard associated with the second threshold value is that the vibration speed of the welding sample is greater than the second threshold value.
  • the corresponding threshold includes a third threshold for the soldering rate of the weld mark area, and the standard associated with the third threshold is: the soldering rate of the weld mark area is less than the third threshold.
  • the welding sample is placed on a vibration isolation platform while the welding sample is vibrating at the resonant frequency.
  • the vibration isolation platform can isolate the interference of environmental vibration and improve the stability and accuracy of the measurement.
  • the vibration generator includes an ultrasonic transducer.
  • the ultrasonic transducer can improve the stability of the measurement and the detection efficiency.
  • the welding sample includes a battery tab-adapter welding joint.
  • the welding quality of a specified part of the battery can be detected.
  • the resonant frequency of the tab-to-adapter welding joint is obtained by the following steps: driving the good tab-to-adapter welding joint to vibrate by a vibration generator, wherein the excitation frequency of the vibration generator gradually changes; detecting the vibration speed of the good tab-to-adapter welding joint under the gradually changing excitation frequency by a vibration detector; and determining the excitation frequency corresponding to the good tab-to-adapter welding joint when the vibration speed is the maximum as the resonant frequency of the tab-to-adapter welding joint.
  • the excitation frequency of the vibration generator is gradually changed in the following manner: the excitation frequency of the vibration generator is increased from the first frequency to the second frequency in a frequency step, or is decreased from the second frequency to the first frequency in a frequency step, wherein the second frequency is greater than the first frequency.
  • the first frequency is 20 kilohertz (kHz)
  • the second frequency is 800 kHz
  • the frequency step is 1 to 5 kHz.
  • an embodiment of the second aspect of the present application provides a welding quality detection system, comprising: a vibration generator, a vibration detector, a memory and a processor, wherein the memory stores instructions; and a processor, the processor being configured to execute instructions to perform operations, the operations comprising: driving the welding sample to vibrate at a resonant frequency via the vibration generator; acquiring vibration data of the welding sample at the resonant frequency detected by the vibration detector; determining at least one vibration parameter of the welding sample based on the vibration data; and determining that a welding defect exists in the welding sample in response to at least one of the at least one vibration parameter satisfying a standard associated with a corresponding threshold.
  • the vibration parameters of the welding sample are directly extracted for defect detection, which has the characteristics of high inspection accuracy, convenience and efficiency.
  • a welding quality inspection system further includes a vibration isolation platform, which is used to carry the welding sample during the period when the welding sample vibrates at the resonant frequency.
  • the vibration isolation platform can isolate the interference of environmental vibration and improve the stability and accuracy of the measurement.
  • the vibration wave generated by the vibration generator is transmitted to the vibration isolation platform along a first direction, and an acute angle ⁇ is formed between the first direction and the surface of the vibration isolation platform supporting the welding sample. Incident on the welding sample at an acute angle can reduce measurement errors and improve the accuracy of detection. At the same time, the acute angle of incidence can make the vibration path longer, and more accurate measurement results can be obtained.
  • the acute angle ⁇ satisfies: 40 degrees (°) ⁇ ⁇ ⁇ 60°. Incident on the welding sample at an angle of 40°-60° can reduce measurement errors and improve detection accuracy. At the same time, incident at an angle of 40°-60° can make the vibration path longer, and more accurate measurement results can be obtained.
  • the vertical distance H between the vibration detector and the welding sample satisfies: 20 mm ⁇ H ⁇ 50 mm.
  • the vibration generator includes an ultrasonic transducer, which is used to generate ultrasonic waves under the stimulation of an excitation signal, and project the ultrasonic waves onto the welding sample to drive the welding sample to vibrate at a resonant frequency.
  • the ultrasonic transducer can improve the stability of the measurement and the detection efficiency to a certain extent.
  • a welding quality detection system further includes a signal generator for generating a voltage signal; and a power amplifier for amplifying the voltage signal to provide an excitation signal.
  • the welding sample includes a battery tab-adapter welding joint.
  • the welding quality of a specified part of the battery can be detected.
  • An embodiment of the third aspect of the present application provides a welding quality detection device, which includes a first module, a second module and a third module, the first module is used to obtain vibration data of a welding sample detected by a vibration detector at a resonant frequency, wherein the resonant frequency is an excitation frequency of the welding sample driven to vibrate by a vibration generator; the second module is used to determine at least one vibration parameter of the welding sample based on the vibration data; and the third module is used to determine that a welding defect exists in the welding sample in response to at least one of the at least one vibration parameter satisfying a standard associated with a corresponding threshold.
  • An embodiment of the fourth aspect of the present application provides a computer-readable storage medium on which instructions are stored.
  • the processor executes the welding quality detection method as described above.
  • An embodiment of the fifth aspect of the present application provides a computer program product, comprising instructions, which, when executed by a processor, causes the processor to execute the welding quality detection method as described above.
  • FIG1 is a schematic flow chart of a welding quality detection method provided in some embodiments of the present application.
  • FIG2 is a schematic diagram of good welding products provided by some embodiments of the present application.
  • FIG3 is a comparison diagram of good welding products and bad welding products provided in some embodiments of the present application.
  • FIG4 is an enlarged schematic diagram of region A in FIG3 before and after shear force stretching provided by some embodiments of the present application;
  • FIG5 is a vibration shape comparison diagram of good welding products and bad welding products provided in some embodiments of the present application.
  • FIG6 is a schematic diagram of the structure of a welding quality detection system provided in some embodiments of the present application.
  • FIG7 is a structural block diagram of an industrial computer provided in some embodiments of the present application.
  • FIG8 is a schematic diagram of the structure of a welding quality detection device provided in some embodiments of the present application.
  • the term "and/or" is only a description of the association relationship of the associated objects, indicating that there may be three relationships.
  • a and/or B can represent: A exists alone, A and B exist at the same time, and B exists alone.
  • the character "/" in this article generally indicates that the associated objects before and after are in an "or" relationship.
  • multiple refers to more than two (including two).
  • multiple groups refers to more than two groups (including two groups), and “multiple pieces” refers to more than two pieces (including two pieces).
  • Power batteries are not only used in energy storage power systems such as hydropower, thermal power, wind power and solar power stations, but also widely used in electric vehicles such as electric bicycles, electric motorcycles, electric cars, as well as military equipment and aerospace and other fields. With the continuous expansion of the application field of power batteries, the market demand is also constantly expanding.
  • the positive and negative electrodes of the batteries need to be welded to the battery case or other connection parts. Multiple batteries may need to be connected in series or in parallel through welding connecting plates.
  • the battery case may need to be welded to complete the sealing. Some batteries with safety protection functions may also need to weld the safety valve or explosion-proof valve to the battery case.
  • the welding quality is particularly important for the quality of the battery. It is necessary to inspect each welding part of the battery to detect welding defects in time and reduce the outflow of batteries with welding defects.
  • the cold-welded or cracked joint When the welding joint of the tab adapter is cold-welded or cracked, the cold-welded or cracked joint will reduce the contact area, significantly reduce the conductivity, and increase the contact resistance, which may cause power loss. At the same time, the increased resistance will increase the heat generated when the current passes through, which may cause the battery to overheat over a long period of time. On the other hand, cracks in the welding joint or cold-welded welds will cause the mechanical strength of the joint to weaken, making the joint easy to break, which may cause serious safety accidents.
  • the inherent acoustic characteristics of the sample can be directly extracted for defect detection.
  • This detection method has high accuracy and improves the detection efficiency to a certain extent.
  • specific acoustic characteristics can be set to conduct in-depth detection and analysis of specific categories or types of defects, which has strong application flexibility.
  • the welding quality detection method disclosed in the embodiment of the present application can be used for non-destructive detection of welding parts in various battery production processes, including but not limited to detecting cold welds or cracks in welding joints of tab adapters.
  • FIG. 1 is a flow chart of a welding quality detection method provided by some embodiments of the present application.
  • the present application provides a welding quality detection method, the method comprising:
  • Resonance frequency refers to the natural frequency at which an object or system can reach the maximum amplitude or vibration speed when driven by an external force. The following relationship is satisfied at resonance:
  • s is the oscillator displacement
  • C is the constant term
  • e is the natural constant
  • k is the stiffness
  • t is the time
  • i is the vibration order
  • v0 is the initial vibration velocity
  • F is the total force of the oscillator
  • m is the mass of the oscillator
  • f0 is the natural frequency of the good welding product
  • f is the ultrasonic excitation frequency.
  • the vibration generator may be a device (e.g., an ultrasonic transducer) that utilizes the characteristics of ultrasound to generate vibrations through the elasticity of an object or the nonlinear effect of a medium.
  • the vibration detector may be an acceleration sensor, a piezoelectric vibration sensor, or a laser vibrometer, which is not specifically limited here.
  • Each vibration parameter satisfies the standard related to the corresponding threshold value, which means that when the preset standard is that the corresponding first vibration parameter is less than the corresponding first threshold value, the welding sample has a first type of welding defect, then in the process of quality inspection, in response to the detected first vibration parameter being less than the corresponding first threshold value, it is determined that the welding sample has a welding defect, or at least the welding sample has a first type of welding defect.
  • the welding sample has a second type of welding defect
  • the process of quality inspection in response to the detected second vibration parameter being less than the corresponding second threshold value, it is determined that the welding sample has a welding defect, or at least the welding sample has a second type of welding defect.
  • the vibration parameters of the welding sample at the resonant frequency By directly extracting the vibration parameters of the welding sample at the resonant frequency for defect detection, it has the characteristics of high detection accuracy, convenience and efficiency. If the welding quality is not good, problems such as fracture or structural damage may occur. If the welding part can keep various vibration parameters stable at the resonant frequency, it means that the welding quality is good. On the contrary, if the vibration parameters are stable at the resonant frequency, it means that the welding quality is good. Under this condition, if each vibration parameter meets the standards associated with the corresponding threshold value, it means that there may be problems in the welding part, which improves the detection rate and detection efficiency of welding defects to a certain extent.
  • the threshold value of at least one vibration parameter is obtained by statistically analyzing the values of at least one vibration parameter of at least one good welding product at a resonance frequency.
  • the good welding product is used to set the standard welding parts.
  • the purpose of setting the vibration parameter threshold is to judge whether the sample to be tested is qualified according to this threshold in the subsequent test.
  • the welding samples to be tested and the good welding products are the pole lugs and the adapter that are welded to each other. Since the pole lugs and the battery cells are already connected before the pole lugs and the adapter are welded, the welding samples to be tested and the good welding products also include the battery cells correspondingly connected to the corresponding pole lugs. It can be understood that the selection of the welding samples to be tested and the good welding products is determined based on the welding position (object) to be detected, and the welding samples to be tested and the good welding products corresponding to different welding positions to be detected may be different from each other.
  • the welding samples and good welding products corresponding to the same welding position to be detected should be based on the same benchmark, that is, if the welding samples to be tested only include the battery cells, pole lugs and the adapter, the good welding products should also only include the battery cells, pole lugs and the adapter.
  • Good welding products are selected to set this threshold because good welding products represent the expected and ideal product status to a certain extent. If the vibration response of a welding sample to be tested is similar to the response of good welding products, then the welding sample can be considered qualified. On the contrary, if the vibration response of the welding sample to be tested is far away from this threshold range, then there may be a problem. For example, there may be a problem of poor welding in the welding sample, which causes the instability of the internal structure and thus produces an abnormal vibration response.
  • the threshold value when obtaining the vibration parameter threshold, may be obtained by statistically analyzing the values of at least one vibration parameter of a plurality of good welding products at the resonance frequency.
  • vibration testing good welding products are used to set the inspection standard.
  • the purpose of setting the threshold value of each vibration parameter is to judge whether the sample to be tested is qualified based on this threshold value in subsequent tests.
  • the accuracy of the threshold values of the vibration parameters can be improved, thereby improving the detection rate of welding defects to a certain extent.
  • the resonant frequency is obtained by detecting the maximum vibration speed of at least one good welding product.
  • the sample vibration signal can reach a peak value, which helps to reduce the impact of noise in the measurement process on the measurement results, thereby improving the measurement accuracy.
  • At least one good weld is obtained by the following steps: obtaining the shear force test results of M welding samples out of N welding samples, wherein the N welding samples are welded under the same process conditions, N and M are integers greater than 1, and M ⁇ N; in response to the shear force test results of the M welding samples each satisfying the good product evaluation index, determining that the remaining N-M welding samples out of the N welding samples are at least one good weld.
  • the welding differences between the same batch of welding samples obtained under the same process conditions are small. Therefore, a part of the welding samples from the same batch obtained under the same process conditions are selected for shear force testing.
  • shear force test results of each welding sample meet the good product evaluation index, it is considered that the welding samples of the batch meet the requirements of good welding products, and the remaining N-M welding samples that have not undergone shear force testing can be determined as good welding products.
  • the same batch of welding samples can be divided into multiple equal parts.
  • a batch of welding samples has 420 pieces, which can be divided into 42 equal parts of 10 pieces each.
  • 1-2 welding samples are taken from each part for shear force test, and the remaining welding samples in each part are treated as good welding products for subsequent inspection.
  • the welding quality of the welding samples to be tested can be better evaluated, thereby achieving non-destructive testing.
  • the shear force test result includes the weld mark residual rate of the welding sample under shear force, wherein the weld mark residual rate is the ratio of the number of residual welds of the welding sample after stretching under shear force to the total number of welds of the welding sample.
  • FIG 2 is a schematic diagram of good welding products provided in some embodiments of the present application.
  • the pole ear 2 and the adapter 3 are connected through a welding joint 4, wherein the pole ear 2 is connected to the battery cell 1, and the connection of the welding joint 4 is one of the structures of the battery assembly.
  • the pole ear 2 and the adapter 3 are tightly connected by welding to form a relatively stable welding joint 4, which can effectively transfer current when the battery is working.
  • the welding quality evaluation of the welding joint 4 (i.e. the aforementioned good product evaluation index) generally relies on the following two indicators: shear force and weld mark residual area.
  • the shear force refers to the force required to directly shear the welding joint 4, and this value is an indicator for evaluating the strength of the welding joint 4.
  • Figure 3 is a comparison diagram of good welding products (left half of Figure 3) and bad welding products (right half of Figure 3) provided by some embodiments of the present application.
  • a layer of weld print area will be formed on the surface of the welding sample, namely, area A and area B in Figure 3.
  • Figure 4 is an enlarged schematic diagram of area A in Figure 3 before and after shear force stretching provided by some embodiments of the present application.
  • the weld print residual rate is the ratio of the number of residual weld points c of the good welding product after the good welding product is stretched under shear force to the total number of weld points c of the good welding product.
  • the good product evaluation indicators include: 100N ⁇ 800N, ⁇ is the shear force borne by the good welding product; 0.5 ⁇ R ⁇ 1, R is the weld mark residual rate of the good welding product.
  • the shear force satisfies 100N ⁇ 800N, which means that the strength of the welded joint 4 has reached the preset standard and can withstand a certain amount of pulling or squeezing in daily use without breaking easily.
  • the total number of welds in the weld mark area is 27, and the number of residual welds c after stretching is 19.
  • Shear force and weld mark residual rate can be used to characterize the shear strength and welding quality in the welded structure, to evaluate the actual performance of the welding quality, and to better evaluate the welding quality of the battery tab and the adapter.
  • At least one vibration parameter includes at least one of a characteristic parameter characterizing a vibration shape of the welding sample, a vibration velocity of the welding sample, and a soldering rate of a weld print zone of the welding sample, wherein the soldering rate is a ratio of an area of a soldering region within the weld print zone to an area of the weld print zone.
  • connection strength between the tab 2 and the adapter 3 is reduced, the constraint of the adapter 3 on the weld print area is weakened, and the vibration speed is significantly increased.
  • the soldering rate of the weld mark area refers to the ratio of the soldering area in the weld mark area to the area of the entire welding contact surface, i.e. the soldering area.
  • the soldering rate directly affects the mechanical properties of the welded joint. Generally speaking, the higher the soldering rate, the greater the strength of the welded joint.
  • the detection accuracy and efficiency of the welding joint can be improved to a certain extent.
  • the characteristic parameter of the mode shape includes the aspect ratio of the mode shape.
  • the aspect ratio of the vibration shape can, to some extent, reflect the elastic characteristics and structural performance of the sample under test during vibration.
  • a stress concentration area will be formed, causing the stiffness of the local structure to change.
  • this change in stiffness will also cause changes in the vibration shape.
  • the more severe the crack the greater the change in the aspect ratio of the vibration shape.
  • Figure 5 is a vibration shape comparison diagram of good welding products and poor welding products provided in some embodiments of the present application.
  • W is the width of the vibration shape
  • H is the height of the vibration shape.
  • the left half of Figure 5 is a vibration shape detection image of a good welding product
  • the right half of Figure 5 is a vibration shape detection image of a poor welding product. It can be seen that the aspect ratio (W/H) of the vibration shape of the poor welding product is reduced to a certain extent compared with that of the good welding product. Therefore, by monitoring the change in the aspect ratio of the vibration shape, it is possible to directly determine whether cracks are found in the welding joint (or even the severity of the cracks).
  • the aspect ratio of the vibration shape is only an example of a characteristic parameter of the vibration shape.
  • other characteristic parameters of the vibration shape may be used as a judgment criterion, such as the area of the vibration shape.
  • the area of the vibration shape may also reflect the elastic characteristics and structural performance of the sample to be tested during vibration. Generally, the more severe the crack, the smaller the area of the vibration shape.
  • the corresponding threshold includes a first threshold for the aspect ratio of the mode shape, and the criterion associated with the first threshold is that the aspect ratio of the mode shape is smaller than the first threshold.
  • the aspect ratios of the vibration shapes of the plurality of good welding products can be obtained by measuring the vibration shapes of the plurality of good welding products at the resonance frequency, and the first threshold can be obtained based on the aspect ratios of the vibration shapes of the plurality of good welding products.
  • the vibrations on both sides of the crack tend to be discrete, and the vibration shape detected will appear abnormal. Therefore, when the aspect ratio of the vibration shape of the welded sample at the resonant frequency is less than the first threshold, the welded joint of the welded sample is cracked, and it is determined that the welded sample has a welding defect.
  • the corresponding threshold includes a second threshold for the vibration speed of the welding sample, and the criterion associated with the second threshold is that the vibration speed of the welding sample is greater than the second threshold.
  • the second threshold interval can be obtained based on the vibration speeds of the plurality of good welding products at the resonance frequency.
  • the connection strength between the tab and the adapter plate decreases, the constraint of the adapter plate on the weld print area weakens, and the vibration speed will be significantly enhanced.
  • the vibration speed of the welding sample at the resonant frequency is greater than the second threshold, there is a cold weld in the welding joint of the welding sample, which means that it is determined that the welding sample has a welding defect.
  • the corresponding threshold includes a third threshold for the soldering rate of the weld mark area, and the standard associated with the third threshold is: the soldering rate of the weld mark area is less than the third threshold.
  • the third threshold interval can be obtained based on the brazing rates of the plurality of good welds at the resonant frequency. Since the higher the brazing rate, the greater the strength of the weld joint. Therefore, when the brazing rate of the welded sample at the resonant frequency is less than the third threshold, the strength of the welded joint of the welded sample is insufficient, that is, it is determined that the welded sample has a welding defect.
  • the welding sample includes a tab-to-transfer piece welding joint of a battery.
  • the good welding products used to measure the resonance frequency and the welding quality judgment threshold also include the battery's tab-adapter welding joint. That is, the resonance frequency and judgment threshold measured for the good welding tab-adapter welding joint will be applied to the welding quality detection of the tab-adapter welding joint of the welding sample.
  • the resonant frequency of the tab-to-adapter plate welding joint is obtained by the following steps: driving the good tab-to-adapter plate welding joint to vibrate by a vibration generator, wherein the excitation frequency of the vibration generator gradually changes; detecting the vibration speed of the good tab-to-adapter plate welding joint under the gradually changing excitation frequency by a vibration detector; and determining the excitation frequency corresponding to the good tab-to-adapter plate welding joint when the vibration speed is maximum as the resonant frequency of the tab-to-adapter plate welding joint.
  • the good quality of the tab-adapter welding joint is obtained by the following steps: obtaining the shear force test results of each of the Y tab-adapter welding joints among the X tab-adapter welding joints, wherein the X tab-adapter welding joints The joints are welded under the same process conditions, X and Y are integers greater than 1, and Y ⁇ X; in response to the shear force test results of each of the Y tab-adapter welding joints satisfying the good product evaluation index, the remaining XY tab-adapter welding joints among the X tab-adapter welding joints are determined to be at least one good tab-adapter welding joint.
  • the welding difference between the same batch of tab-adapter welding joints welded under the same process conditions is small, so by selecting a part of the same batch of tab-adapter welding joints welded under the same process conditions for shear force testing, when the shear force test results of each of the tab-adapter welding joints satisfy the good product evaluation index, it is considered that the tab-adapter welding joints of the batch meet the requirements of welding good products, and the remaining XY tab-adapter welding joints that have not been subjected to the shear force test can be determined as good tab-adapter welding joints.
  • the excitation frequency of the vibration generator gradually changes in the following manner: the excitation frequency of the vibration generator increases from a first frequency to a second frequency in a frequency step, or decreases from the second frequency to the first frequency in a frequency step, wherein the second frequency is greater than the first frequency.
  • Resonance frequency refers to the natural frequency at which an object or system can reach the maximum amplitude or vibration speed when driven by an external force. The following relationship is satisfied at resonance:
  • s is the oscillator displacement
  • C is the constant term
  • e is the natural constant
  • k is the stiffness
  • t is the time
  • i is the vibration order
  • v0 is the initial vibration velocity
  • F is the total force of the oscillator
  • m is the mass of the oscillator
  • f0 is the natural frequency of the good welding product
  • ff is the ultrasonic excitation frequency.
  • the vibration generator may be a device (e.g., an ultrasonic transducer) that utilizes the characteristics of ultrasound to generate vibrations through the elasticity of an object or the nonlinear effect of a medium.
  • the vibration detector may be an acceleration sensor, a piezoelectric vibration sensor, or a laser vibrometer, which is not specifically limited here.
  • the first frequency is 20 kHz
  • the second frequency is 800 kHz
  • the frequency step is 1 to 5 kHz.
  • FIG. 6 is a schematic diagram of the structure of a welding quality detection system provided by some embodiments of the present application.
  • the present application provides a welding quality detection system, including: a vibration generator 8, a vibration detector 7 and an industrial computer 11, wherein the industrial computer 11 includes a memory, the memory stores instructions; and a processor, the processor is configured to execute instructions to perform operations, the operations including: driving the welding sample 6 to vibrate at a resonant frequency via the vibration generator 8; obtaining vibration data of the welding sample 6 at a resonant frequency detected by the vibration detector 7; based on the vibration data, determining at least one vibration parameter of the welding sample 6; and in response to at least one of the at least one vibration parameter meeting the standard associated with the corresponding threshold, determining that the welding sample 6 has a welding defect.
  • FIG. 7 is a block diagram of an industrial computer provided in some embodiments of the present application.
  • the industrial computer 11 is intended to represent various forms of digital electronic computer devices, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers.
  • the components shown herein, their connections and relationships, and their functions are only examples.
  • the industrial computer 11 includes a processor 111, which can perform various appropriate actions and processes according to a computer program stored in a read-only memory (ROM) 112 or an instruction loaded from a storage unit 118 into a random access memory (RAM) 113.
  • ROM read-only memory
  • RAM random access memory
  • various programs and data required for the operation of the industrial computer 11 can also be stored.
  • the computing unit 111, the ROM 112, and the RAM 113 are connected to each other via a bus 114.
  • An input/output (I/O) interface 115 is also connected to the bus 114.
  • the input unit 116 can be any type of device that can input information to the industrial computer 11.
  • the input unit 116 can receive input digital or character information, and generate key signal input related to user settings and/or function control of the electronic device, and can include but is not limited to a mouse, a keyboard, a touch screen, a track pad, a track ball, a joystick, a microphone, and/or a remote control.
  • the output unit 117 can be any type of device that can present information, and can include but is not limited to a display, a speaker, a video/audio output terminal, a vibrator, and/or a printer.
  • the storage unit 118 can include but is not limited to a disk and an optical disk.
  • the communication unit 119 allows the industrial computer 11 to exchange information/data with other devices through a computer network such as the Internet and/or various telecommunication networks, and can include but is not limited to a modem, a network card, an infrared communication device, a wireless communication transceiver, and/or a chipset.
  • the processor 111 may be a variety of general and/or special processing components with processing and computing capabilities. Some examples of the processor 111 include, but are not limited to, a central processing unit (CPU), a graphics processing unit (GPU), various special artificial intelligence (AI) computing chips, various computing units running machine learning model algorithms, digital signal processors (DSPs), and any suitable processor, controller, microcontroller, etc.
  • the processor 111 executes the various methods and processes described above, such as the welding quality detection method in the above embodiments.
  • a welding quality inspection system directly extracts the vibration parameters of welding samples at the resonant frequency for defect detection, and has the characteristics of high detection accuracy, convenience and efficiency. If the welding quality is not good, problems such as fracture or structural damage may occur. If the welding part can keep the various vibration parameters stable at the resonant frequency, it means that the welding quality is good. On the contrary, if the various vibration parameters meet the standards associated with the corresponding thresholds at the resonant frequency, it means that there may be problems at the welding part, which improves the detection rate and detection efficiency of welding defects to a certain extent.
  • a welding quality inspection system further includes a vibration isolation platform 5 , and the vibration isolation platform 5 is used to support the welding sample during the period when the welding sample vibrates at the resonant frequency.
  • the vibration isolation platform 5 can isolate and control the vibration interference of the external environment on the welding sample during the vibration test, so as to improve the accuracy of the test.
  • the vibration isolation platform 5 can be an air-floating vibration isolation platform, which isolates the platform from its bracket through air springs to isolate external vibrations.
  • the vibration isolation platform 5 can isolate the interference of environmental vibration and improve the stability and accuracy of measurement.
  • the vibration wave generated by the vibration generator is transmitted to the vibration isolation platform along a first direction, and the first direction forms an acute angle ⁇ with the surface of the vibration isolation platform supporting the welding sample.
  • a vibration generator is a device that creates vibrations at a specific excitation frequency.
  • the vibration waves produced by the vibration generator are usually the physical manifestation of the excitation frequency.
  • the vibration frequency of the vibration wave determines the speed of the vibration.
  • the vibration wave generated by the vibration generator generally propagates in the same direction as the vibration direction of the vibration sound generator, so the vibration direction of the vibration generator determines the original propagation direction of the vibration wave.
  • the sharp angle of incidence on the welding sample can reduce the measurement error and improve the accuracy of the detection. At the same time, the sharp angle of incidence can make the vibration path longer, so more accurate measurement results can be obtained.
  • the acute angle ⁇ satisfies: 40° ⁇ 60°.
  • the welding sample is incident at an angle of 40°-60°, which can reduce the measurement error and improve the accuracy of the detection.
  • the vibration path can be longer at an angle of 40°-60°, so more accurate measurement results can be obtained.
  • a vertical distance H between the vibration detector and the welding sample satisfies: 20 mm ⁇ H ⁇ 50 mm.
  • the vertical distance H between the vibration detector and the welding sample can be the minimum distance between the detection port of the vibration detector and the surface of the welding sample closest to the vibration sensor, wherein the detection port of the vibration detector can be the opening of the vibration detector detection position shell, or it can be the plane where the sensor of the vibration detector is located.
  • the attenuation of the detection signal can be reduced, and the interference of environmental noise can be reduced, thereby improving the detection accuracy.
  • the vibration generator includes an ultrasonic transducer 8, which is used to generate ultrasonic waves under the excitation of an excitation signal and project the ultrasonic waves onto the welding sample 6 to drive the welding sample 6 to vibrate at a resonant frequency.
  • the ultrasonic transducer 8 is used to convert the voltage signal into ultrasonic waves and project them onto the weld joint.
  • the ultrasonic transducer 8 can provide very precise and consistent power and can well control the frequency and amplitude of the vibration. Compared with other types of vibration generators, the ultrasonic transducer 8 has a higher energy conversion efficiency, is small in size, easy to install and maintain, has a fast response speed, and can generate strong vibrations in a short time.
  • the ultrasonic transducer 8 Since the ultrasonic transducer 8 does not need to be in direct contact with the welding sample to generate vibration, the mechanical connection between the vibration generator and the welding sample is avoided to a certain extent. Therefore, the ultrasonic transducer 8 can improve the measurement stability and detection efficiency to a certain extent.
  • a welding quality detection system further includes a signal generator 10 for generating a voltage signal; and a power amplifier 9 for amplifying the voltage signal to provide an excitation signal.
  • the signal generator 10 and the power amplifier 9 are often used in pairs.
  • the signal generator 10 generates the required voltage signal, and then the power amplifier 9 amplifies the signal so that the excitation signal has enough energy to drive the subsequent device to perform a specific operation.
  • the welding sample includes a tab-to-transfer piece welding joint of a battery.
  • the welded sample when the welded good product includes the battery cell 1, the tab 2, the adapter 3 and the welding joint 4, the welded sample also includes the battery cell, the tab, the adapter and the welding joint.
  • the welded sample and welded good product corresponding to the same welding position to be tested should be based on the same reference.
  • tab-adapter welding joint is only an example, and in other embodiments, the welding quality can be tested for other appropriate welding positions of the battery.
  • FIG8 is a schematic diagram of the structure of a welding quality detection device provided in some embodiments of the present application.
  • the present application provides a welding quality detection device 800 , including:
  • the first module 801 is used to obtain vibration data of a welding sample at a resonant frequency detected by a vibration detector, wherein the resonant frequency is an excitation frequency at which the welding sample is driven to vibrate by a vibration generator.
  • the second module 802 is used to determine at least one vibration parameter of the welding sample based on the vibration data.
  • the third module 803 is used to determine that a welding defect exists in the welding sample in response to at least one of the at least one vibration parameter satisfying a criterion associated with a corresponding threshold.
  • the first module 801 , the second module 802 and the third module 803 in the welding quality inspection device 800 can respectively correspond to steps S110 to S130 in FIG. 1 , the details of each aspect thereof will not be repeated here.
  • the functions of the various modules discussed herein can be divided into multiple modules, and/or at least some functions of multiple modules can be combined into a single module.
  • the specific module discussed herein performs an action including the specific module itself performing the action, or alternatively the specific module calls or otherwise accesses another component or module that performs the action (or performs the action in conjunction with the specific module). Therefore, the specific module that performs an action can include the specific module itself that performs the action and/or another module that the specific module calls or otherwise accesses to perform the action.
  • modules described above with respect to FIG. 8 may be implemented in hardware or in hardware in combination with software and/or firmware.
  • these modules may be implemented as computer program codes/instructions configured to be executed in one or more processors and stored in a computer-readable storage medium.
  • these modules may be implemented as hardware logic/circuits.
  • the hardware logic/circuit may include an integrated circuit chip (which includes a processor (e.g., a central processing unit (CPU), a microcontroller, a microprocessor, a digital signal processor (DSP), etc.), a memory, one or more communication interfaces, and/or one or more components in other circuits), and may execute the received program code and/or include embedded firmware to perform functions.
  • a processor e.g., a central processing unit (CPU), a microcontroller, a microprocessor, a digital signal processor (DSP), etc.
  • DSP digital signal processor
  • An embodiment of the present application also provides a computer-readable storage medium on which instructions are stored.
  • the processor executes the welding quality detection method in any of the above embodiments.
  • Computer-readable storage media include volatile and non-volatile, removable and non-removable media implemented by any method or technology for storing information, such as computer-readable instructions, data structures, program modules or other data.
  • Computer-readable storage media include but are not limited to RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD), or other optical storage device, magnetic cassette, magnetic tape, magnetic disk storage device or other magnetic storage device, or any other non-transmission medium that can be used to store information for access by a computer device.
  • communication media can implement computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transmission mechanism.
  • Computer-readable storage media defined herein do not include communication media.
  • the present application also provides a computer program product, including instructions, which, when executed by a processor, cause the processor to execute the welding quality detection method in any of the above embodiments.
  • a computer program product including instructions, which, when executed by a processor, cause the processor to execute the welding quality detection method in any of the above embodiments.
  • the embodiments of the present application provide a welding quality detection method, including:
  • Vibration data of a welding sample detected by a scanning laser vibrometer lens at a resonant frequency is obtained, wherein the resonant frequency is an excitation frequency at which the welding sample is driven to vibrate by a vibration generator; based on the vibration data, at least one vibration parameter of the welding sample is determined, the vibration parameter including at least one of an aspect ratio of a vibration shape characterizing the welding sample, a vibration velocity of the welding sample, and a soldering rate of a weld mark area of the welding sample; in response to at least one of the above at least one vibration parameter satisfying a standard associated with a corresponding threshold value, it is determined that the welding sample has a welding defect.
  • the threshold value corresponding to the at least one vibration parameter is obtained by statistically analyzing the values of at least one vibration parameter of a plurality of good welding products at the resonance frequency.
  • the multiple good welding products are copper tab-adapter plate welding joints and aluminum tab-adapter plate welding joints: through tensile testing, the average shear forces of the copper tab-adapter plate welding joints and the aluminum tab-adapter plate welding joints are 256N and 231N respectively, and the residual areas of weld marks are 90% and 85% respectively, and they are selected as good welding products.
  • a total of 420 good welding products were selected, and the 420 good welding products were classified according to the copper tab-adapter welding joint and the aluminum tab-adapter welding joint, and placed in batches on the air-floating vibration isolation platform.
  • the ultrasonic transducer excitation frequency drives each batch of good welding products to vibrate, the excitation frequency range meets 20-800kHz, the frequency interval is 1-5kHz, the ultrasonic incident angle is 40-60°, and the scanning laser vibration lens is used to detect the sample vibration signal at a distance of about 20-50mm from the good welding product.
  • the excitation frequency range meets 20-800kHz
  • the frequency interval is 2kHz
  • the ultrasonic incident angle is 45°
  • the scanning laser vibration lens is used to detect the sample vibration signal at a distance of about 40mm from the good welding product.
  • the average resonance frequency of the good welding of the copper tab-adapter welding joint is 301kHz
  • the average resonance frequency of the good welding of the aluminum tab-adapter welding joint is 165kHz.
  • the vibration speed of multiple good welding products at the resonant frequency is measured, and the vibration speeds of both are less than 1E-05m/s, that is, the second threshold value is Th2 ⁇ 1E-05m/s.
  • the soldering rate of multiple good welding products at the resonant frequency is measured, and the soldering rate of both meets the third threshold value Th3 ⁇ 0.5.
  • the ultrasonic transducer excitation frequency is maintained at the resonant frequency corresponding to the good welding product, and the vibration parameters of the multiple welding samples at the resonant frequency are measured respectively, and compared with at least one of the first threshold, the second threshold and the third threshold.
  • At least one of the above at least one vibration parameter meeting the standard associated with the corresponding threshold that is, when the aspect ratio of the vibration shape of the welding sample is less than the first threshold, the vibration speed of the welding sample is greater than the second threshold, and the welding sample is When the soldering rate of the weld mark area of the welding sample is less than the third threshold value and at least one of the three conditions is met, it is output that the welding sample has welding defects, thereby detecting and intercepting quality defects in the corresponding welding sample.

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Abstract

本申请提供一种焊接质量检测方法、焊接质量检测系统、焊接质量检测装置、计算机可读存储介质和计算机程序产品，属于电池技术领域。其中，焊接质量检测方法包括：获取由振动检测器检测的焊接样品在共振频率下的振动数据，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率；基于振动数据，确定焊接样品的至少一个振动参数；以及响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。通过直接提取焊接样品的振动参数进行缺陷检测，具有检测精度高、检测效率快的特点。

Description

焊接质量检测方法、装置、计算机可读存储介质和产品
交叉引用
本申请引用于2023年08月15日递交的名称为“焊接质量检测方法、装置、计算机可读存储介质和产品”的第202311027006.3号中国专利申请，其通过引用被全部并入本申请。
技术领域
本申请涉及电池技术领域，尤其涉及一种焊接质量检测方法、一种焊接质量检测系统、一种焊接质量检测装置、一种计算机可读存储介质和一种计算机程序产品。
背景技术
节能减排是汽车产业可持续发展的关键，电动车辆由于其节能环保的优势成为汽车产业可持续发展的重要组成部分。对于电动车辆而言，电池技术又是关乎其发展的一项重要因素。
在电池的生产过程中，电池的各个部件之间的焊接质量会影响生产出的电池的可靠性，若存在焊接质量的电池流入市场端，则可能造成产品安全风险。
发明内容
本申请旨在至少解决背景技术中存在的技术问题之一。为此，本申请的一个目的在于提供一种焊接质量检测方法及装置，以一定程度上提高电池制造过程中焊接问题的检出率。
本申请第一方面的实施例提供一种焊接质量检测方法，该方法包括：获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率；基于振动数据，确定焊接样品的至少一个振动参数；以及响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
本申请实施例的技术方案中，通过直接提取焊接样品在共振频率下的振动参数进行缺陷检测，具有检测精度高、便捷高效等特点。如果焊接部位能够在共振频率下保持各项振动参数稳定，说明焊接质量良好，反之，如果在共振频率下，各项振动参数满足与 相应阈值相关联的标准，则说明焊接部位可能出现问题，一定程度上提高了焊接缺陷的检出率。
在一些实施例中，至少一个振动参数各自的阈值是通过对至少一个焊接良品在共振频率下的至少一个振动参数各自的取值分别进行统计而得到的。在振动测试中，焊接良品是用来设定检测标准的，设定振动参数各自的阈值的目的是为了在后续的测试中，可以依据这个阈值来判断待测的焊接样品是否合格。
在一些实施例中，共振频率是通过对至少一个焊接良品的最大振动速度进行检测而得到的。通过获取共振频率作为激励频率，能够使样品振动信号到达峰值，有助于降低测量过程中的噪声对测量结果的影响，从而提高测量精度。
在一些实施例中，至少一个焊接良品是通过以下步骤得到的：获取N个焊接样品中的M个焊接样品各自的剪切力测试结果，其中，N个焊接样品是在相同工艺条件下焊接的，N和M为大于1的整数，且M＜N；响应于M个焊接样品各自的剪切力测试结果均满足良品评价指标，确定N个焊接样品中的剩余N-M个焊接样品为至少一个焊接良品。由于电芯制造的一致性较高，在相同工艺条件下焊接得到的同一批焊接样品之间的焊接差异度较小，因此通过选取在相同工艺条件下焊接得到的同一批次的焊接样品中的其中一部分进行剪切力测试，当焊接样品各自的剪切力测试结果均满足良品评价指标，则认为该批次的焊接样品均符合焊接良品的要求，则可以将剩余N-M个未经过剪切力测试的焊接样品确定为焊接良品。在一些实施例中，对于M个焊接样品中的每个焊接样品，剪切力测试结果包括该焊接样品在剪切力下的焊印残留率，其中，焊印残留率为该焊接样品在剪切力下进行拉伸后的残留焊点数量与该焊接样品的总焊点数量之比。通过基于剪切力和焊印残留率评价电池极耳与转接片的焊接质量，从而获得焊接良品，能够更好的对电池极耳与转接片的焊接质量进行评价。
在一些实施例中，对于M个焊接样品中的每个焊接样品，良品评价指标包括：100牛顿(N)≤τ≤800N，τ为该焊接良品承受的剪切力；0.5≤R≤1，R为该焊接良品的焊印残留率。剪切力和焊印残留率可用于表征焊接结构中的抗剪切强度和焊接质量，用于评估焊接质量的实际性能，能够更好的对电池极耳与转接片的焊接质量进行评价。
在一些实施例中，至少一个振动参数包括表征焊接样品的振形的特征参数、焊接样品的振动速度和焊接样品的焊印区的钎着率中的至少一者，其中，钎着率为焊印区内的钎着区域的面积与焊印区的面积之比。
通过表征焊接样品的振形的特征参数、焊接样品的振动速度和焊接样品的焊印区的钎着率中的至少一者是否满足与相应阈值相关联的标准，能一定程度上提高焊接接头的检测精度和检测效率。
在一些实施例中，振形的特征参数包括振形的宽高比。通过监控振形的宽高比的变化，从而直接判断焊接接头是否发现裂纹，以及裂纹的严重程度，提高检测效率。
在一些实施例中，相应阈值包括针对振形的宽高比的第一阈值，并且与第一阈值相关联的标准为：振形的宽高比小于第一阈值。通过表征焊接样品的振形的宽高比是否小于第一阈值，能快速的判定焊接样品的焊接接头是否发生裂纹，能一定程度上提高焊接接头的检测精度和检测效率。
在一些实施例中，相应阈值包括针对焊接样品的振动速度的第二阈值，并且与第二阈值相关联的标准为：焊接样品的振动速度大于第二阈值。通过表征焊接样品的振动速度是否大于第二阈值，能快速的判定焊接样品的焊接接头是否发生虚焊，能一定程度上提高焊接接头的检测精度和检测效率。
在一些实施例中，相应阈值包括针对焊印区的钎着率的第三阈值，并且与第三阈值相关联的标准为：焊印区的钎着率小于第三阈值。通过表征焊接样品的钎着率是否小于第三阈值，能快速的判定焊接样品的焊接接头的连接强度是否达到预设标准，能一定程度上提高焊接接头的检测精度和检测效率。
在一些实施例中，焊接样品在共振频率下发生振动期间，焊接样品被放置于隔振平台上。通过隔振平台，能够隔绝环境振动的干扰，提高测量的稳定性和准确性。
在一些实施例中，振动发生器包括超声换能器。通过超声换能器能够提高测量的稳定性和检测效率。
在一些实施例中，焊接样品包括电池的极耳-转接片焊接接头。通过获取电池的极耳-转接片焊接接头的振动数据，能够实现针对电池的指定部位的焊接质量的检测。
在一些实施例中，极耳-转接片焊接接头的共振频率是通过以下步骤得到的：通过振动发生器驱动极耳-转接片焊接接头良品发生振动，其中，振动发生器的激励频率逐渐变化；通过振动检测器检测极耳-转接片焊接接头良品在逐渐变化的激励频率下的振动速度；以及确定极耳-转接片焊接接头良品在振动速度最大时对应的激励频率作为极耳-转接片焊接接头的共振频率。通过振动发生器的激励频率逐渐变化，能够容易判断在哪个激励频率下极耳-转接片焊接接头良品的振动速度最大，从而得到极耳-转接片焊接接头的共振频率。
在一些实施例中，振动发生器的激励频率按以下方式逐渐变化：振动发生器的激励频率以频率步长从第一频率递增至第二频率，或者以频率步长从第二频率递减至第一频率，其中，第二频率大于第一频率。以频率步长逐渐增加激励频率，可以观察到极耳-转接片焊接接头良品在不同激励频率下的响应情况，减少过度激励，并能够容易判断在哪个激励频率下极耳-转接片焊接接头良品的振动速度最大，从而得到极耳-转接片焊接接头的共振频率。
在一些实施例中，第一频率为20千赫兹(kHz)，第二频率为800kHz，并且频率步长为1至5kHz。通过设置合适的频率步长，可以找到较为准确的共振频率，从而提高检测准确性。
在一些实施例中，本申请第二方面的实施例提供了一种焊接质量检测系统，包括：振动发生器、振动检测器、存储器和处理器，其中，存储器存储有指令；以及处理器，处理器被配置为执行指令以执行操作，该操作包括：经由振动发生器驱动焊接样品在共振频率下发生振动；获取由振动检测器检测的焊接样品在共振频率下的振动数据；基于振动数据，确定焊接样品的至少一个振动参数；以及响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
通过提供一种焊接质量检测系统，直接提取焊接样品的振动参数进行缺陷检测，具有检测精度高、便捷高效等特点。
在一些实施例中，一种焊接质量检测系统还包括隔振平台，隔振平台用于在焊接样品在共振频率下发生振动期间承载焊接样品。通过隔振平台，能够隔绝环境振动的干扰，提高测量的稳定性和准确性。
在一些实施例中，振动发生器产生的振动波沿第一方向传递至隔振平台，第一方向与隔振平台承载焊接样品的表面之间成锐角θ。以锐角入射焊接样品，可以减少测量误差，提高检测的精准度。同时，锐角入射可以使得振动的路径更长，可以获取到较为准确的测量结果。
在一些实施例中，锐角θ满足：40度(°)≤θ≤60°。以40°-60°的角度入射焊接样品，可以减少测量误差，提高检测的精准度。同时，以40°-60°的角度入射可以使得振动的路径更长，可以获取到较为准确的测量结果。
在一些实施例中，振动检测器与焊接样品之间的垂直距离H满足：20毫米(mm)≤H≤50mm。通过调节振动检测器与焊接样品之间的垂直距离，可以减少检测信号的衰减，同时降低环境噪声的干扰，从而提高检测精度。
在一些实施例中，振动发生器包括超声换能器，超声换能器用于在激励信号的激励下生成超声波，并将超声波投射至焊接样品上以驱动焊接样品在共振频率下发生振动。通过超声换能器能够一定程度上提高测量的稳定性和检测效率。
在一些实施例中，一种焊接质量检测系统还包括信号发生器，用于产生电压信号；以及功率放大器，用于放大电压信号以提供激励信号。
在一些实施例中，焊接样品包括电池的极耳-转接片焊接接头。通过获取电池的极耳-转接片焊接接头的振动数据，能够实现针对电池的指定部位的焊接质量的检测。
本申请第三方面的实施例提供一种焊接质量检测装置，其包括第一模块、第二模块和第三模块，第一模块用于获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率；第二模块用于基于振动数据，确定焊接样品的至少一个振动参数；以及第三模块用于响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
本申请第四方面的实施例提供一种计算机可读存储介质，其上存储有指令，指令被处理器执行时，使处理器执行如上述的焊接质量检测方法。
本申请的第五方面的实施例提供一种计算机程序产品，包括指令，该指令被处理器执行时，使处理器执行如上述的焊接质量检测方法。
上述说明仅是本申请技术方案的概述，为了能够更清楚了解本申请的技术手段，而可依照说明书的内容予以实施，并且为了让本申请的上述和其它目的、特征和优点能够更明显易懂，以下特举本申请的具体实施方式。
附图说明
在附图中，除非另外规定，否则贯穿多个附图相同的附图标记表示相同或相似的部件或元素。这些附图不一定是按照比例绘制的。应该理解，这些附图仅描绘了根据本申请公开的一些实施方式，而不应将其视为是对本申请范围的限制。为了更清楚地说明本申请实施例的技术方案，下面将对本申请实施例中所需要使用的附图作简单地介绍，显而易见地，下面所描述的附图仅仅是本申请的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据附图获得其他的附图。
图1为本申请一些实施例提供的焊接质量检测方法的流程示意图；
图2为本申请一些实施例提供的焊接良品的示意图；
图3为本申请一些实施例提供的焊接良品和焊接劣品的对比图；
图4为本申请一些实施例提供的图3中A区域在剪切力拉伸前后的放大示意图；
图5为本申请一些实施例提供的焊接良品和焊接劣品的振形对比图；
图6为本申请一些实施例提供的焊接质量检测系统的结构示意图；
图7为本申请一些实施例提供的工控机的结构框图；
图8为本申请一些实施例提供的焊接质量检测装置的结构示意图。
具体实施方式
下面将结合附图对本申请技术方案的实施例进行详细的描述。以下实施例仅用于更加清楚地说明本申请的技术方案，因此只作为示例，而不能以此来限制本申请的保护范围。
除非另有定义，本文所使用的所有的技术和科学术语与属于本申请的技术领域的技术人员通常理解的含义相同；本文中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本申请；本申请的说明书和权利要求书及上述附图说明中的术语“包括”和“具有”以及它们的任何变形，意图在于覆盖不排他的包含。
在本申请实施例的描述中，技术术语“第一”、“第二”等仅用于区别不同对象，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量、特定顺序或主次关系。在本申请实施例的描述中，“多个”的含义是两个以上，除非另有明确具体的限定。
在本文中提及“实施例”意味着，结合实施例描述的特定特征、结构或特性可以包含在本申请的至少一个实施例中。在说明书中的各个位置出现该短语并不一定均是指相同的实施例，也不是与其它实施例互斥的独立的或备选的实施例。本领域技术人员显式地和隐式地理解的是，本文所描述的实施例可以与其它实施例相结合。
在本申请实施例的描述中，术语“和/或”仅仅是一种描述关联对象的关联关系，表示可以存在三种关系，例如A和/或B，可以表示：单独存在A，同时存在A和B，单独存在B这三种情况。另外，本文中字符“/”，一般表示前后关联对象是一种“或”的关系。
在本申请实施例的描述中，术语“多个”指的是两个以上(包括两个)，同理，“多组”指的是两组以上(包括两组)，“多片”指的是两片以上(包括两片)。
在本申请实施例的描述中，技术术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、 “水平”、“顶”、“底”、“内”、“外”、“顺时针”、“逆时针”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请实施例和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请实施例的限制。
在本申请实施例的描述中，除非另有明确的规定和限定，技术术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；也可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本申请实施例中的具体含义。
目前，从市场形势的发展来看，动力电池的应用越加广泛。动力电池不仅被应用于水力、火力、风力和太阳能电站等储能电源系统，而且还被广泛应用于电动自行车、电动摩托车、电动汽车等电动交通工具，以及军事装备和航空航天等多个领域。随着动力电池应用领域的不断扩大，其市场的需求量也在不断地扩增。
电池在生产的过程中，电池的正极和负极需要焊接到电池壳体或者其他连接部位，多个电池之间可能需要通过焊接连接片进行串联或并联，电池壳体可能需要焊接完成封闭，一些具备安全保护功能的电池，可能还需要将安全阀或防爆阀焊接在电池壳体上。而其中焊接质量对于电池的品质而言尤为重要，需要对电池各个焊接部位进行检测以及时发现焊接缺陷，减少存在焊接缺陷的电池的流出。
其中当极耳转接片焊接接头发生虚焊或者焊接接头发生裂纹时，虚焊或裂纹会导致接触面积变小，电导率显著降低，接触电阻反而会增大，从而可能会引发电能损耗，同时电阻增大会导致电流通过时发热量增加，长时间下来可能会引发电池过热。另一方面，焊接接头裂纹或者焊缝虚焊，会造成接头的机械强度变薄，使得接头容易断裂，有可能造成严重的安全事故。
基于以上考虑，为了解决电池焊接缺陷检测准确度和检测效率的问题，可以采用直接提取样品固有声学特征进行缺陷检测，该检测方式精确度高，也一定程度上提高了检测的效率。同时能够设定特定的声学特征，对特定类别或类型的缺陷进行深入检测和分析，具有较强的应用灵活性。
本申请实施例公开的焊接质量检测方法，可以用与各种电池生产过程中的焊接部位的无损检测，包括但不限于可以用于对极耳转接片的焊接接头发生虚焊或者焊接接头发生裂纹的情况进行检测。
请参照图1，图1为本申请一些实施例提供的焊接质量检测方法的流程示意图。本申请实施例提供了一种焊接质量检测方法，该方法包括：
S110，获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率；
S120，基于振动数据，确定焊接样品的至少一个振动参数；以及
S130，响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
共振频率是指一个物体或系统在受到外力驱动时，能达到振幅或振动速度最大的固有频率。共振时满足如下关系式：
其中，s为振子位移，C为常数项，e为自然常数，k为刚度，t为时间，i为振动阶数，v0为初始振动速度，F为振子总力，m为振子质量，f0为焊接良品固有频率，f为超声激励频率。
作为一种可行的实施方式，振动发生器可以为利用超声波的特性，通过物体的弹性或者介质的非线性效应产生振动的发生装置(例如，超声波换能器)。振动检测器可以为加速度传感器、压电振动传感器、激光测振仪，在此不做特殊限定。
各项振动参数满足于相应阈值相关的标准意味着当预设的标准为对应的第一振动参数小于相应的第一阈值时，焊接样品存在第一类焊接缺陷，则在质量检测的过程中响应于检测到的第一振动参数小于相应的第一阈值，确定焊接样品存在焊接缺陷，或至少确定焊接样品存在第一类焊接缺陷。同时，当预设的标准为对应的第二振动参数大于相应的第二阈值时，焊接样品存在第二类焊接缺陷，则在质量检测的过程中响应于检测到的第二振动参数小于相应的第二阈值，确定焊接样品存在焊接缺陷，或至少确定焊接样品存在第二类焊接缺陷。可以理解的是，由于不同的振动参数对应的相应阈值，以及相关联的标准可能彼此不相同，因此本申请中的满足相关联的标准可以为大于相应阈值和/或小于相应阈值。
通过直接提取焊接样品在共振频率下的振动参数进行缺陷检测，具有检测精度高、便捷高效等特点。如果焊接质量不好，可能会出现断裂或结构破损等问题，如果焊接部位能够在共振频率下保持各项振动参数稳定，说明焊接质量良好，反之如果在共振频率 下，各项振动参数满足与相应阈值相关联的标准，则说明焊接部位可能出现问题，一定程度上提高了焊接缺陷的检出率和检测效率。
根据本申请的一些实施例，至少一个振动参数各自的阈值是通过对至少一个焊接良品在共振频率下的至少一个振动参数各自的取值分别进行统计而得到的。
在本申请中，焊接良品是用来设定标准的焊接件。设定振动参数阈值的目的是为了在后续的测试中，可以依据这个阈值来判断待测样品是否合格。
当检测的对象为极耳与转接片的焊接头的焊接质量时，待测的焊接样品和焊接良品均为相互焊接好的极耳与转接片，由于在极耳与转接片焊接之前，极耳与电芯已经连接，因此待测的焊接样品和焊接良品还包括与相应极耳对应连接的电芯。可以理解的是，待测的焊接样品和焊接良品的选取是基于待检测的焊接位置(对象)而确定的，不同的待检测的焊接位置对应的待测的焊接样品和焊接良品可能彼此不相同。同一待检测的焊接位置对应的焊接样品和焊接良品应基于同一基准，也即若待测的焊接样品只包括电芯、极耳和转接片，则焊接良品也应只包括电芯、极耳和转接片。
选取焊接良品来设定这个阈值，是因为焊接良品一定程度上代表了预期的、理想的产品状态。如果一个待测的焊接样品的振动响应与焊接良品的响应相近，则可以认为这个焊接样品是合格的。反之，如果待测的焊接样品的振动响应远离了这个阈值范围，那么可能就存在问题。例如，可能该焊接样品中出现了焊接不良的问题，造成了内部结构的不稳定，从而产生了异常的振动响应。
作为一种可行的实施方式，在获取振动参数阈值时，可以采用多个焊接良品在共振频率下的至少一个振动参数各自的取值分别进行统计而得到。
在振动测试中，焊接良品是用来设定检测标准的。设定振动参数各自的阈值的目的是为了在后续的测试中，可以依据这个阈值来判断待测样品是否合格。
通过多个焊接良品的测量数据，能够提高振动参数各自阈值的准确性，从而一定程度上提高焊接缺陷的检出率。
根据本申请的一些实施例，共振频率是通过对至少一个焊接良品的最大振动速度进行检测而得到的。
实际检测过程中，由于各种环境因素会引入不必要的噪声，这种噪声通常是随机的，频率分布相对均匀。当整个检测过程在一个特定的共振频率上进行时，可以大幅提升该频率信号的幅度，其他频率的噪声幅度则相对较小，这就达到了降噪的效果。同时，使用共振频率可以提高信号的选择性和灵敏度，从而提高测量精度。
通过获取共振频率作为激励频率，能够使样品振动信号到达峰值，有助于降低测量过程中的噪声对测量结果的影响，从而提高测量精度。
根据本申请的一些实施例，至少一个焊接良品是通过以下步骤得到的：获取N个焊接样品中的M个焊接样品各自的剪切力测试结果，其中，N个焊接样品是在相同工艺条件下焊接的，N和M为大于1的整数，且M＜N；响应于M个焊接样品各自的剪切力测试结果均满足良品评价指标，确定N个焊接样品中的剩余N-M个焊接样品为至少一个焊接良品。
由于电芯制造的一致性较高，在相同工艺条件下焊接得到的同一批焊接样品之间的焊接差异度较小，因此通过选取在相同工艺条件下焊接得到的同一批次的焊接样品中的其中一部分进行剪切力测试，当焊接样品各自的剪切力测试结果均满足良品评价指标，则认为该批次的焊接样品均符合焊接良品的要求，则可以将剩余N-M个未经过剪切力测试的焊接样品确定为焊接良品。
可以理解的是，相同工艺条件中焊接的环境未发生变化，焊接参数保持一致，以获取理论上各个参数相同的同一批焊接样品。
作为一种可行的实施方式，可以将同一批焊接样品分为多个等份，例如，一批焊接样品的数量为420件，可以将其分为每份10件的42等份，在每一等份中抽取1-2件焊接样品进行剪切力测试，将每一等份中剩余的焊接样品作为焊接良品进行后续的检测。
通过选取焊接良品，将焊接良品作为后续检测的评价指标，能够更好的对待测的焊接样品的焊接质量进行评价，从而实现无损检测。
根据本申请的一些实施例，对于M个焊接样品中的每个焊接样品，剪切力测试结果包括该焊接样品在剪切力下的焊印残留率，其中，焊印残留率为该焊接样品在剪切力下进行拉伸后的残留焊点数量与该焊接样品的总焊点数量之比。
请参照图2，图2为本申请一些实施例提供的焊接良品的示意图。在电池制作过程中，极耳2与转接片3是通过焊接接头4进行连接的，其中极耳2与电芯1连接，而焊接接头4的连接是电池组件的结构之一。在正常情况下，极耳2与转接片3通过焊接实现紧密连接，形成一个相对稳定的焊接接头4，可以在电池工作时有效地传递电流。
而焊接接头4的焊接质量评估(也即前述的良品评价指标)一般依赖以下两个方面的指标：剪切力和焊印残留面积。其中剪切力是指将焊接接头4直接剪切开时所需的力，这个值是评价焊接接头4强度的指标。
请参照图3-4，图3为本申请一些实施例提供的焊接良品(图3左半部分)和焊接劣品(图3右半部分)的对比图。在焊接过程中，焊接样品表面会形成一层焊印区，也即图3中的A区域和B区域。图4为本申请一些实施例提供的图3中A区域在剪切力拉伸前后的放大示意图。焊印残留率为焊接良品在剪切力下进行拉伸后，焊接良品的残留的焊点c的数量与焊接良品的总的焊点c的数量之比，如图4所示，焊印区总的焊点数量为27个，拉伸后的残留的焊点c的数量为19个，则该焊接接头的焊印残留面积＝19/27*100％＝70.4％，其值大于50％，也即该焊接接头为焊接良品。如果这个百分比在50％至100％之间，说明接头的焊接面大部分或者全部参与了焊接，焊接的质量较高。如果这个比例较低，可能说明焊接接头的质量存在问题，焊接接头的强度可能不达标。
通过基于剪切力和焊印残留率评价电池极耳与转接片的焊接质量，从而获得焊接良品，能够更好的对电池极耳与转接片的焊接质量进行评价。
根据本申请的一些实施例，对于M个焊接样品中的每个焊接样品，良品评价指标包括：100N≤τ≤800N，τ为该焊接良品承受的剪切力；0.5≤R≤1，R为该焊接良品的焊印残留率。
一般来说，剪切力满足了100N≤τ≤800N，说明焊接接头4的结实程度达到了预设的标准，能够在日常使用中承受一定的拉扯或者挤压，不会轻易断裂。
如图4所示，焊印区总的焊点数量为27个，拉伸后的残留的焊点c的数量为19个，则该焊接接头的焊印残留面积＝19/27*100％＝70.4％，其值大于50％，也即该焊接接头为焊接良品。如果这个百分比在50％至100％之间，说明接头的焊接面大部分或者全部参与了焊接，焊接的质量较高。如果这个比例较低，可能说明焊接接头的质量存在问题，焊接接头的强度可能不达标。
剪切力和焊印残留率可用于表征焊接结构中的抗剪切强度和焊接质量，用于评估焊接质量的实际性能，能够更好的对电池极耳与转接片的焊接质量进行评价。
根据本申请的一些实施例，至少一个振动参数包括表征焊接样品的振形的特征参数、焊接样品的振动速度和焊接样品的焊印区的钎着率中的至少一者，其中，钎着率为焊印区内的钎着区域的面积与焊印区的面积之比。
当焊接接头4发生虚焊时，极耳2与转接片3的连接强度降低，转接片3对焊印区约束减弱，振动速度显著增强。
当焊接接头4发生裂纹时，裂纹两侧的振动趋于离散，检测得到的振形会出现异形。
焊印区的钎着率是指焊印区内的钎着区域面积与整个焊接接触面也即焊印区的面积的比值。钎着率直接影响焊接接头的机械性能，一般来说，钎着率越高，焊接接头的强度越大。
通过表征焊接样品的振形的特征参数、焊接样品的振动速度和焊接样品的焊印区的钎着率中的至少一者是否满足与相应阈值相关联的标准，能一定程度上提高焊接接头的检测精度和检测效率。
根据本申请的一些实施例，振形的特征参数包括振形的宽高比。
振形的宽高比在某种程度上能够反映待测样品在振动时的弹性特性和结构性能。当焊接接头出现裂纹时，会形成应力集中区域，使得局部结构的刚度发生变化。而在振动时，这种刚度的变化也会引起振形的变化，一般情况下，裂纹越严重，引起的振形宽高比变化也越大。
请参照图5，图5为本申请一些实施例提供的焊接良品和焊接劣品的振形对比图。在图5中，W为振形的宽度，H为振形的高度。图5的左半部分为焊接良品的振形检测图像，图5右半部分为焊接劣品的振形检测图像。可以看到，相对于焊接良品，焊接劣品的振形的宽高比(W/H)一定程度地缩小了。因此，可以通过监控振形的宽高比的变化，从而直接判断焊接接头是否发现裂纹(甚至裂纹的严重程度)。
应当理解，振形的宽高比只是振形的特征参数的一个示例，在其他实施例中，还可以采用振形的其他特征参数作为判断标准，例如振形的面积等。与振形的宽高比类似，振形的面积也可以反映待测样品在振动时的弹性特性和结构性能。一般情况下，裂纹越严重，振形的面积越小。
根据本申请的一些实施例，相应阈值包括针对振形的宽高比的第一阈值，并且与第一阈值相关联的标准为：振形的宽高比小于第一阈值。
可以通过对多个焊接良品在共振频率下的振形的测量结果，得到多个焊接良品的振形的宽高比，基于多个焊接良品的振形的宽高比得到第一阈值。
由于当焊接接头发生裂纹时，裂纹两侧的振动趋于离散，检测得到的振形会出现异形。因此当焊接样品在共振频率下的振形的宽高比小于第一阈值时，则焊接样品的焊接接头发生裂纹，也即确定焊接样品存在焊接缺陷。
通过表征焊接样品的振形的宽高比是否小于第一阈值，能快速的判定焊接样品的焊接接头是否发生裂纹，能一定程度上提高焊接接头的检测精度和检测效率。
根据本申请的一些实施例，相应阈值包括针对焊接样品的振动速度的第二阈值，并且与第二阈值相关联的标准为：焊接样品的振动速度大于第二阈值。
可以通过对多个焊接良品在共振频率下的振动速度，基于多个焊接良品的振动速度得到第二阈值区间。
由于极耳与转接片的连接强度降低，转接片对焊印区约束减弱，振动速度会显著增强，则当焊接样品在共振频率下的振动速度大于第二阈值时，焊接样品的焊接接头存在虚焊，也即确定焊接样品存在焊接缺陷。
通过表征焊接样品的振动速度是否大于第二阈值，能快速的判定焊接样品的焊接接头是否发生虚焊，能一定程度上提高焊接接头的检测精度和检测效率。
根据本申请的一些实施例，相应阈值包括针对焊印区的钎着率的第三阈值，并且与第三阈值相关联的标准为：焊印区的钎着率小于第三阈值。
可以通过对多个焊接良品在共振频率下的钎着率，基于多个焊接良品的钎着率得到第三阈值区间。由于钎着率越高，焊接接头的强度越大。因此当焊接样品在共振频率下的钎着率小于第三阈值时，焊接样品的焊接接头的强度不足，也即确定焊接样品存在焊接缺陷。
通过表征焊接样品的钎着率是否小于第三阈值，能快速的判定焊接样品的焊接接头的连接强度是否达到预设标准，能一定程度上提高焊接接头的检测精度和检测效率。
根据本申请的一些实施例，焊接样品包括电池的极耳-转接片焊接接头。
应当理解，在这样的实施例中，用于测量共振频率和焊接质量判断阈值的焊接良品也包括电池的极耳-转接片焊接接头。也即，针对焊接良品的极耳-转接片焊接接头测量的共振频率和判断阈值将应用于焊接样品的极耳-转接片焊接接头的焊接质量检测。
通过获取电池的极耳-转接片焊接接头的振动数据，能够实现针对电池中指定部位的焊接质量进行检测。
根据本申请的一些实施例，极耳-转接片焊接接头的共振频率是通过以下步骤得到的：通过振动发生器驱动极耳-转接片焊接接头良品发生振动，其中，振动发生器的激励频率逐渐变化；通过振动检测器检测极耳-转接片焊接接头良品在逐渐变化的激励频率下的振动速度；以及确定极耳-转接片焊接接头良品在振动速度最大时对应的激励频率作为极耳-转接片焊接接头的共振频率。
极耳-转接片焊接接头良品是通过以下步骤得到的：获取X个极耳-转接片焊接接头中的Y个极耳-转接片焊接接头各自的剪切力测试结果，其中，X个极耳-转接片焊接 接头是在相同工艺条件下焊接的，X和Y为大于1的整数，且Y＜X；响应于Y个极耳-转接片焊接接头各自的剪切力测试结果均满足良品评价指标，确定X个极耳-转接片焊接接头中的剩余X-Y个极耳-转接片焊接接头为至少一个极耳-转接片焊接接头良品。由于电芯制造的一致性较高，在相同工艺条件下焊接得到的同一批极耳-转接片焊接接头之间的焊接差异度较小，因此通过选取在相同工艺条件下焊接得到的同一批次的极耳-转接片焊接接头中的其中一部分进行剪切力测试，当极耳-转接片焊接接头各自的剪切力测试结果均满足良品评价指标，则认为该批次的极耳-转接片焊接接头均符合焊接良品的要求，则可以将剩余X-Y个未经过剪切力测试的极耳-转接片焊接接头确定为极耳-转接片焊接接头良品。
通过振动发生器的激励频率逐渐变化，能够容易判断在哪个激励频率下极耳-转接片焊接接头良品的振动速度最大，从而得到极耳-转接片焊接接头的共振频率。
根据本申请的一些实施例，振动发生器的激励频率按以下方式逐渐变化：振动发生器的激励频率以频率步长从第一频率递增至第二频率，或者以频率步长从第二频率递减至第一频率，其中，第二频率大于第一频率。
共振频率是指一个物体或系统在受到外力驱动时，能达到振幅或振动速度最大的固有频率。共振时满足如下关系式：
其中，s为振子位移，C为常数项，e为自然常数，k为刚度，t为时间，i为振动阶数，v0为初始振动速度，F为振子总力，m为振子质量，f0为焊接良品固有频率，ff为超声激励频率。
作为一种可行的实施方式，振动发生器可以为利用超声波的特性，通过物体的弹性或者介质的非线性效应产生振动的发生装置(例如，超声波换能器)。振动检测器可以为加速度传感器、压电振动传感器、激光测振仪，在此不做特殊限定。
以频率步长逐渐增加激励频率，可以观察到极耳-转接片焊接接头良品在不同激励频率下的响应情况，减少过度激励，并能够容易判断在哪个激励频率下极耳-转接片焊接接头良品的振动速度最大，从而得到极耳-转接片焊接接头的共振频率。
根据本申请的一些实施例，第一频率为20kHz，第二频率为800kHz，并且频率步长为1至5kHz。
通过设置合适的频率步长，可以找到较为准确的共振频率，从而提高检测的准确性。
请参照图6，图6为本申请一些实施例提供的焊接质量检测系统的结构示意图。本申请实施例提供了一种焊接质量检测系统，包括：振动发生器8、振动检测器7和工控机11，其中，工控机11包括存储器，存储器存储有指令；以及处理器，处理器被配置为执行指令以执行操作，该操作包括：经由振动发生器8驱动焊接样品6在共振频率下发生振动；获取由振动检测器7检测的焊接样品6在共振频率下的振动数据；基于振动数据，确定焊接样品6的至少一个振动参数；以及响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品6存在焊接缺陷。
请参照图7，图7为本申请一些实施例提供的工控机的结构框图。工控机11旨在表示各种形式的数字电子的计算机设备，诸如，膝上型计算机、台式计算机、工作台、个人数字助理、服务器、刀片式服务器、大型计算机、和其它适合的计算机。本文所示的部件、它们的连接和关系、以及它们的功能仅仅作为示例。
如图7所示，工控机11包括处理器111，其可以根据存储在只读存储器(ROM)112中的计算机程序或者从存储单元118加载到随机访问存储器(RAM)113中的指令，来执行各种适当的动作和处理。在RAM113中，还可存储工控机11操作所需的各种程序和数据。计算单元111、ROM112以及RAM113通过总线114彼此相连。输入/输出(I/O)接口115也连接至总线114。
工控机11中的多个部件连接至I/O接口115，包括：输入单元116、输出单元117、存储单元118以及通信单元119。输入单元116可以是能向工控机11输入信息的任何类型的设备，输入单元116可以接收输入的数字或字符信息，以及产生与电子设备的用户设置和/或功能控制有关的键信号输入，并且可以包括但不限于鼠标、键盘、触摸屏、轨迹板、轨迹球、操作杆、麦克风和/或遥控器。输出单元117可以是能呈现信息的任何类型的设备，并且可以包括但不限于显示器、扬声器、视频/音频输出终端、振动器和/或打印机。存储单元118可以包括但不限于磁盘、光盘。通信单元119允许工控机11通过诸如因特网的计算机网络和/或各种电信网络与其他设备交换信息/数据，并且可以包括但不限于调制解调器、网卡、红外通信设备、无线通信收发机和/或芯片组。
处理器111可以是各种具有处理和计算能力的通用和/或专用处理组件。处理器111的一些示例包括但不限于中央处理单元(CPU)、图形处理单元(GPU)、各种专用的人工智能(AI)计算芯片、各种运行机器学习模型算法的计算单元、数字信号处理器(DSP)、 以及任何适当的处理器、控制器、微控制器等。处理器111执行上文所描述的各个方法和处理，例如上述各实施例中的焊接质量检测方法。
一种焊接质量检测系统通过直接提取焊接样品在共振频率下的振动参数进行缺陷检测，具有检测精度高、便捷高效等特点。如果焊接质量不好，可能会出现断裂或结构破损等问题，如果焊接部位能够在共振频率下保持各项振动参数稳定，说明焊接质量良好，反之如果在共振频率下，各项振动参数满足与相应阈值相关联的标准，则说明焊接部位可能出现问题，一定程度上提高了焊接缺陷的检出率和检测效率。
继续参考图6，根据本申请的一些实施例，一种焊接质量检测系统还包括隔振平台5，隔振平台5用于在焊接样品在共振频率下发生振动期间承载焊接样品。
隔振平台5可以在振动测试中隔离和控制外部环境对焊接样品的振动干扰，以此来提高测试的准确性。作为一种可行的实施方式，隔振平台5可以为气浮隔振平台，通过空气弹簧将平台与其支架隔离，来隔离外部的振动。
通过隔振平台5，能够隔绝环境振动的干扰，提高测量的稳定性和准确性。
根据本申请的一些实施例，振动发生器产生的振动波沿第一方向传递至隔振平台，第一方向与隔振平台承载焊接样品的表面之间成锐角θ。
振动发生器是一种设备，用于创建特定的激励频率的振动，振动发生器产生的振动波通常是激励频率的物理表现。振动波的振动频率决定了振动的速度。
振动发生器产生的振动波一般是沿着与振动发声器振动方向相同的方向传播的，因此振动发生器的振动方向决定了振动波的原始传播方向。
以锐角入射焊接样品，可以减少测量误差，提高检测的精准度。同时，锐角入射可以使得振动的路径更长，可以获取到较为准确的测量结果。
根据本申请的一些实施例，锐角θ满足：40°≤θ≤60°。
以40°-60°的角度入射焊接样品，可以减少测量误差，提高检测的精准度。同时，以40°-60°的角度入射可以使得振动的路径更长，可以获取到较为准确的测量结果。
根据本申请的一些实施例，振动检测器与焊接样品之间的垂直距离H满足：20mm≤H≤50mm。
振动检测器与焊接样品之间的垂直距离H可以为，振动检测器的检测口与焊接样品距离振动传感器最近的表面之间的最小距离，其中，振动检测器的检测口可以为振动检测器检测位置外壳的开口处，也可以为振动检测器的传感器所在平面。
通过调节振动检测器与焊接样品之间的垂直距离，可以减少检测信号的衰减，同时降低环境噪声的干扰，从而提高检测精度。
根据本申请的一些实施例，振动发生器包括超声换能器8，超声换能器8用于在激励信号的激励下生成超声波，并将超声波投射至焊接样品6上以驱动焊接样品6在共振频率下发生振动。
超声换能器8用于将电压信号转换为超声波，并投射到焊接接头上。超声换能器8可以提供非常精确和一致的动力，能够很好地控制振动的频率和振幅。相比其他类型的振动发生器，超声换能器8的能量转化效率更高，且体积小易于安装和维护，响应速度也较快，可以在短时间内产生强烈的振动。
由于超声换能器8产生振动不需要与焊接样品直接接触，在一定程度上避免了振动发生器与焊接样品之间的机械连接，因此通过超声换能器8能够一定程度上提高测量的稳定性和检测效率。
根据本申请的一些实施例，一种焊接质量检测系统还包括信号发生器10，用于产生电压信号；以及功率放大器9，用于放大电压信号以提供激励信号。
信号发生器10和功率放大器9常常配对使用，信号发生器10产生所需的电压信号，然后功率放大器9放大这个信号，使得激励信号有足够的能量去驱动后续设备进行特定的操作。
根据本申请的一些实施例，焊接样品包括电池的极耳-转接片焊接接头。
参考图2，当焊接良品包括电芯1、极耳2、转接片3和焊接接头4时，焊接样品也包括电芯、极耳、转接片和焊接接头。同一待检测的焊接位置对应的焊接样品和焊接良品应基于同一基准。
通过获取电池的极耳-转接片焊接接头的振动数据，能够实现针对电池中指定部位的焊接质量进行检测。
应当理解，极耳-转接片焊接接头只是一个示例，在其他实施例中，可以针对电池的其他适当的焊接部位进行焊接质量的检测。
请参照图8，图8为本申请一些实施例提供的焊接质量检测装置的结构示意图。本申请实施例提供了一种焊接质量检测装置800，包括：
第一模块801，用于获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率。
第二模块802，用于基于振动数据，确定焊接样品的至少一个振动参数。
第三模块803，用于响应于至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
由于焊接质量检测装置800中的第一模块801、第二模块802和第三模块803可以分别对应于如图1中的步骤S110至S130，因此这里不再赘述其各个方面的细节。
应当注意，本文讨论的各个模块的功能可以分为多个模块，和/或多个模块的至少一些功能可以组合成单个模块。本文讨论的特定模块执行动作包括该特定模块本身执行该动作，或者替换地该特定模块调用或以其他方式访问执行该动作(或结合该特定模块一起执行该动作)的另一个组件或模块。因此，执行动作的特定模块可以包括执行动作的该特定模块本身和/或该特定模块调用或以其他方式访问的、执行动作的另一模块。
还应当理解，本文可以在软件硬件元件或程序模块的一般上下文中描述各种技术。上面关于图8描述的各个模块可以在硬件中或在结合软件和/或固件的硬件中实现。例如，这些模块可以被实现为计算机程序代码/指令，该计算机程序代码/指令被配置为在一个或多个处理器中执行并存储在计算机可读存储介质中。可替换地，这些模块可以被实现为硬件逻辑/电路。硬件逻辑/电路可以包括集成电路芯片(其包括处理器(例如，中央处理单元(Central Processing Unit，CPU)、微控制器、微处理器、数字信号处理器(Digital Signal Processor，DSP)等)、存储器、一个或多个通信接口、和/或其他电路中的一个或多个部件)，并且可以执行所接收的程序代码和/或包括嵌入式固件以执行功能。
本申请实施例还提供了一种计算机可读存储介质，其上存储有指令，指令被处理器执行时，使处理器执行如上任意实施例中的焊接质量检测方法。
计算机可读存储介质包括通过用于存储信息的任何方法或技术实施的易失性和非易失性、可移除和不可移除介质，信息诸如是计算机可读指令、数据结构、程序模块或者其他数据。计算机可读存储介质包括而不限于RAM、ROM、EEPROM、闪存或其他存储器技术，CD-ROM、数字通用盘(DVD)、或其他光学存储装置，磁盒、磁带、磁盘存储装置或其他磁性存储设备，或者可以被用来存储信息以供计算机设备访问的任何其他非传送介质。与此相对，通信介质可以在诸如载波或其他传送机制之类的已调制数据信号中实现计算机可读指令、数据结构、程序模块或其他数据。本文所定义的计算机可读存储介质不包括通信介质。
本申请实施例还提供了一种计算机程序产品，包括指令，该指令被处理器执行时，使处理器执行如上任意实施例中的焊接质量检测方法。这样的计算机程序或指令已经在上文关于图7进行了描述，为了简洁起见，在此不再赘述。
根据本申请的一些实施例，如图1-6所示，本申请实施例提供了一种焊接质量检测方法，包括了：
获取由扫描式激光测振镜头检测的焊接样品在共振频率下的振动数据，其中，共振频率为经由振动发生器驱动焊接样品发生振动的激励频率；基于振动数据，确定焊接样品的至少一个振动参数，振动参数包括表征焊接样品的振形的宽高比、焊接样品的振动速度和焊接样品的焊印区的钎着率中的至少一者；响应于以上至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定焊接样品存在焊接缺陷。
其中，在测量焊接样品之前，通过多个焊接良品在共振频率下的至少一个振动参数各自的取值进行统计得到至少一个振动参数对应的阈值。
多个焊接良品中包括铜质的极耳-转接片焊接接头和铝质的极耳-转接片焊接接头：通过拉伸测试，铜质的极耳-转接片焊接接头和铝质的极耳-转接片焊接接头的平均剪切力分别为256N与231N，焊印残留面积分别为90％与85％，选取为焊接良品。
作为一种可行的实施方式，选取焊接良品共420个，420个焊接良品依据铜质的极耳-转接片焊接接头和铝质的极耳-转接片焊接接头分类，并分批次放在气浮隔振平台上。通过超声换能器激励频率驱动各个批次的焊接良品发生振动，激励频率范围满足20～800kHz，频率间隔为1-5kHz，超声入射角度40-60°，采用扫描式激光测振镜头距离焊接良品约20-50mm处探测样品振动信号。作为一种可行的实施方式，激励频率范围满足20～800kHz，频率间隔为2kHz，超声入射角度45°，采用扫描式激光测振镜头距离焊接良品约40mm处探测样品振动信号。获得铜质的极耳-转接片焊接接头的焊接良品的平均共振频率为301kHz，和铝质的极耳-转接片焊接接头焊接良品的平均共振频率为165kHz。
将超声换能器激励频率设置为焊接良品对应的共振频率，分别测得多个焊接良品在共振频率下的振动参数，并基于多个焊接良品的振形的宽高比得到第一阈值Th1＝W/H≥0.8，其中，W为振形的宽度，H为振形的高度。测得多个焊接良品在共振频率下的振动速度，两者的振动速度均小于1E-05m/s，也即第二阈值为Th2≤1E-05m/s。测得多个焊接良品在共振频率下的钎着率，两者的钎着率均满足第三阈值Th3≥0.5。
将超声换能器激励频率保持为焊接良品对应的共振频率，分别测得多个焊接样品在共振频率下的振动参数，并将其与第一阈值、第二阈值和第三阈值中的至少一者进行比较，响应于以上至少一个振动参数中的至少一者满足与相应阈值相关联的标准，也即，当焊接样品的振形的宽高比小于第一阈值、焊接样品的振动速度大于第二阈值，以及焊 接样品焊印区的钎着率小于第三阈值，三个条件中至少满足一者时，则输出焊接样品存在焊接缺陷，从而检测并拦截了相应焊接样品中的质量缺陷。
最后应说明的是：以上各实施例仅用以说明本申请的技术方案，而非对其限制；尽管参照前述各实施例对本申请进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本申请各实施例技术方案的范围，其均应涵盖在本申请的权利要求和说明书的范围当中。尤其是，只要不存在结构冲突，各个实施例中所提到的各项技术特征均可以任意方式组合起来。本申请并不局限于文中公开的特定实施例，而是包括落入权利要求的范围内的所有技术方案。

Claims (26)

  1. 一种焊接质量检测方法，包括：
    获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，所述共振频率为经由振动发生器驱动所述焊接样品发生振动的激励频率；
    基于所述振动数据，确定所述焊接样品的至少一个振动参数；以及
    响应于所述至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定所述焊接样品存在焊接缺陷。
  2. 根据权利要求1所述的方法，其中，所述至少一个振动参数各自的阈值是通过对至少一个焊接良品在所述共振频率下的所述至少一个振动参数各自的取值分别进行统计而得到的。
  3. 根据权利要求1或2所述的方法，其中，所述共振频率是通过对至少一个焊接良品的最大振动速度进行检测而得到的。
  4. 根据权利要求2或3所述的方法，其中，所述至少一个焊接良品是通过以下步骤得到的：
    获取N个焊接样品中的M个焊接样品各自的剪切力测试结果，其中，所述N个焊接样品是在相同工艺条件下焊接的，N和M为大于1的整数，且M＜N；
    响应于所述M个焊接样品各自的剪切力测试结果均满足良品评价指标，确定所述N个焊接样品中的剩余N-M个焊接样品为所述至少一个焊接良品。
  5. 根据权利要求4所述的方法，其中，对于所述M个焊接样品中的每个焊接样品，所述剪切力测试结果包括该焊接样品在剪切力下的焊印残留率，其中，所述焊印残留率为该焊接样品在所述剪切力下进行拉伸后的残留焊点数量与该焊接样品的总焊点数量之比。
  6. 根据权利要求5所述的方法，其中，对于所述M个焊接样品中的每个焊接样品，所述良品评价指标包括：
    100N≤τ≤800N，τ为该焊接良品承受的剪切力；
    0.5≤R≤1，R为该焊接良品的焊印残留率。
  7. 根据权利要求1-6中任一项所述的方法，其中，所述至少一个振动参数包括表征所述焊接样品的振形的特征参数、所述焊接样品的振动速度和所述焊接样品的焊印区的钎着率中的至少一者，其中，所述钎着率为所述焊印区内的钎着区域的面积与所述焊印区的面积之比。
  8. 根据权利要求7所述的方法，其中，所述振形的特征参数包括所述振形的宽高比。
  9. 根据权利要求8所述的方法，其中，所述相应阈值包括针对所述振形的宽高比的第一阈值，并且与所述第一阈值相关联的标准为：所述振形的宽高比小于所述第一阈值。
  10. 根据权利要求7-9中任一项所述的方法，其中，所述相应阈值包括针对所述焊接样品的振动速度的第二阈值，并且与所述第二阈值相关联的标准为：所述焊接样品的振动速度大于所述第二阈值。
  11. 根据权利要求7-10中任一项所述的方法，其中，所述相应阈值包括针对所述焊印区的钎着率的第三阈值，并且与所述第三阈值相关联的标准为：所述焊印区的钎着率小于所述第三阈值。
  12. 根据权利要求1-11中任一项所述的方法，其中，所述焊接样品包括电池的极耳-转接片焊接接头。
  13. 根据权利要求12所述的方法，其中，所述极耳-转接片焊接接头的共振频率是通过以下步骤得到的：
    通过所述振动发生器驱动极耳-转接片焊接接头良品发生振动，其中，所述振动发生器的激励频率逐渐变化；
    通过所述振动检测器检测所述极耳-转接片焊接接头良品在逐渐变化的所述激励频率下的振动速度；以及
    确定所述极耳-转接片焊接接头良品在振动速度最大时对应的激励频率作为所述极耳-转接片焊接接头的共振频率。
  14. 根据权利要求13所述的方法，其中，所述振动发生器的激励频率按以下方式逐渐变化：
    所述振动发生器的激励频率以频率步长从第一频率递增至第二频率，或者以所述频率步长从所述第二频率递减至所述第一频率，其中，所述第二频率大于所述第一频率。
  15. 根据权利要求14所述的方法，其中，所述第一频率为20kHz，所述第二频率为800kHz，并且所述频率步长为1至5kHz。
  16. 一种焊接质量检测系统，包括：
    振动发生器；
    振动检测器；
    存储器，所述存储器存储有指令；以及
    处理器，所述处理器被配置为执行所述指令以执行操作，所述操作包括：
    获取由所述振动检测器检测的焊接样品在共振频率下的振动数据，其中，所述共振频率为经由所述振动发生器驱动所述焊接样品发生振动的激励频率；
    基于所述振动数据，确定所述焊接样品的至少一个振动参数；以及
    响应于所述至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定所述焊接样品存在焊接缺陷。
  17. 根据权利要求16所述的焊接质量检测系统，其中，还包括隔振平台，所述隔振平台用于在所述焊接样品在所述共振频率下发生振动期间承载所述焊接样品。
  18. 根据权利要求17所述的焊接质量检测系统，其中，所述振动发生器产生的振动波沿第一方向传递至所述隔振平台，所述第一方向与所述隔振平台承载所述焊接样品的表面之间成锐角θ。
  19. 根据权利要求18所述的焊接质量检测系统，其中，所述锐角θ满足：40°≤θ≤60°。
  20. 根据权利要求16-19中任一项所述的焊接质量检测系统，其中，所述振动检测器与所述焊接样品之间的垂直距离H满足：20mm≤H≤50mm。
  21. 根据权利要求16-20中任一项所述的焊接质量检测系统，其中，所述振动发生器包括超声换能器，所述超声换能器用于在激励信号的激励下生成超声波，并将所述超声波投射至所述焊接样品上以驱动所述焊接样品在所述共振频率下发生振动。
  22. 根据权利要求21所述的焊接质量检测系统，其中，还包括：
    信号发生器，用于产生电压信号；以及
    功率放大器，用于放大所述电压信号以提供所述激励信号。
  23. 根据权利要求16-22中任一项所述的焊接质量检测系统，其中，所述焊接样品包括电池的极耳-转接片焊接接头。
  24. 一种焊接质量检测装置，包括：
    第一模块，用于获取由振动检测器检测的焊接样品在共振频率下的振动数据，其中，所述共振频率为经由所述振动发生器驱动所述焊接样品发生振动的激励频率；
    第二模块，用于基于所述振动数据，确定所述焊接样品的至少一个振动参数；以及
    第三模块，用于响应于所述至少一个振动参数中的至少一者满足与相应阈值相关联的标准，确定所述焊接样品存在焊接缺陷。
  25. 一种计算机可读存储介质，其上存储有指令，所述指令被处理器执行时，使所述处理器执行权利要求1-15中任一项所述的方法。
  26. 一种计算机程序产品，包括指令，所述指令被处理器执行时，使所述处理器执行权利要求1-15中任一项所述的方法。
PCT/CN2023/122918 2023-08-15 2023-09-28 焊接质量检测方法、装置、计算机可读存储介质和产品 Ceased WO2025035553A1 (zh)

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