Market Application Background
With the development of new energy in automobile market, laser welding industry grows rapidly. Laser welding is applied widely in the middle and behind production process of power battery, including key process in battery module connection piece welding, explosion-proof valve welding, and pole lug welding and so on.
The new energy automobile power battery welding quality directly affects reliability and usage lifetime of battery connection. Therefore, it is very important to optimize traditional laser welding technology process.
What's problem in traditional laser welding
When it is welding complex trajectory at high-speed, for traditional screw guide servo motor system, welding head may appear overprocessing, too large weld depth to width ratio and other problems. Especially at the chamfer position, welding head's motion speed will become lower, which means the speed is not stable during welding, then it will cause laser processing energy density is not even, then the welding effect is influenced.
How Zmotion solve it:
In this kind of situation, Zmotion developed one open laser galvanometer motion controller ZMC408SCAN-V2. ZMC408SCAN-V2 combines with galvanometer, laser and axis control , and it is high-efficient and stable, open and easy to use, so it is the first choice of new energy automobile manufacture enterprise. At the same time, it supports many functions that can ensure laser processing trajectory smoothing, promote quality and performance, such as, high-speed PSO, PWM, speed look-ahead, etc.
When ZMC408SCAN-V2 is applied in high power laser galvanometer system to do soft connection piece welding, it can reach circular trajectory welding at a speed of 200-300 ms /s. Even in some complicated spiral processing trajectory, like, S curve, helical curve, it also can avoid problems existed in traditional system.
(1) Problems:
Traditional laser welding solution problems
it is hard to operate the standard laser system software, so it is hard to meet non-standard customized requirements for production line.
motion control card and laser galvanometer card are controlled independently, so it is hard to develop.
laser welding speed is limited in servo platform, so the processing effect of complex trajectory in high-speed is not good.
(2) Solution:
Zmotion solution
--solution design--
--solution example--
it uses teach editing method to generate processing trajectory automatically, and it supports spiral, involute and other welding technology curves.
a. how to operate:
configure laser parameters according to laser types and wiring.
correct galvanometer distortion through correction software, and save correction parameters.
edit corresponding welding trajectory and technology according to product welding size.
set processing speed and delay technology parameter.
trigger marking, and observe welding effect, and adjust parameters.
b. how the welding effect is:
c. why the solution can solve problems:
linkage interpolation between SCAN axis and servo axis.
laser power can be modified flexibly: freely adjust corresponding laser parameters according to laser type and wiring configuration.
processing speed and delay parameter can be set to control welding precisely for different materials and welding requirements.
multiple development methods are supported: it supports C++, C#, etc., and it provides specialized laser function library and application examples, manufactures can develop quickly.
helical trajectory welding function: different welding depth ratio can be realized through light spot along with welding direction, which means no need to change external optical path conditions.
d. what's the core technology for solution:
--spiral trajectory--
In high-energy density beam welding, a big welding depth ratio is one feature of laser welding. If you don't want the depth ratio is too large, for example, when it is welding battery module connection piece, generally a bigger width is needed to add current carrying area. Now, if you want to reduce the width (use thinner battery posts to gain more cell space), please use spiral trajectory to weld, then different welding width ratio can be obtained through high-speed rotation of light spot along with welding direction when external optical condition is not changed.
--laser power control--
In laser welding, power control (analog voltage, PWM modulation) is extremely important.
Power in laser processing includes two aspects, power control and synchronous control between power and motion.
laser power: generate suitable control signals to control power required by laser.
synchronous control between power and motion: power follows with processing position or speed changes to ensure consistent processing quality.
The independent laser galvanometer motion controller ZMC408SCAN-V2 integrates laser control, galvanometer control and bus axis / pulse axis control, it can help you achieve high-effective and precise EtherCAT motion control + laser galvanometer control.
--ZMC408SCAN-V2 Features--
a. 6-64 axes motion control (pulse + EtherCAT bus)
b. support 1D/2D/3D PSO function, then achieve vision fly-shooting, precise dispensing, and laser energy control
c. laser galvanometer control and motion control are combined, then laser processing system with multi-axis linkage method can be built flexibly
d. multi-dimensional position synchronous output PSO is valid, and there are 24 general inputs and 20 general outputs, and 4 are high-speed color code latching, 4 are PSO outputs and 8 are PWM outputs
Open lase galvanometer motion controller ZMC408SCAN-V2 is one of the key parts in new energy automobile power battery module connection-piece welding. In such rapid development of Chinese new energy automobile market, this technology provides corresponding solution for traditional problems.
Through teaching edit method, welding trajectory will be generated automatically, and there are many development methods and specialized laser function library, which can help device system manufacture develop products quickly.
In addition, ZMC408SCAN-V2 supports control functions required by many kinds of laser welding technology, then it can overcome problems in traditional laser welding system, welding quality and efficiency both can be promoted.
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Zmotion Technology focuses on development of motion control technology and general motion control products, it is a national high and new technology enterprise. Due to its concentration and hard work in motion control technology, ZMOTION already become one of the fastest growing industrial motion control companies in China, and is also the rare company who has managed core technologies of motion control and real time industrial control software completely. Here, Zmotion provides motion controller, motion control card, vision motion controller, expansion module and HMI. In addition, there is one program software developed by Zmotion -- ZDevelop. It is a good choice for you to program and compile. And program through upper computer, there is PC manual.
Zmotion Technology provides motion control card, motion controller, vision motion controller, expansion module and HMI. ( more keywords for Zmotion: EtherCAT motion control card, EtherCAT motion controller, motion control system, vision controller, motion control PLC, robot controller, vision positioning...)
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