Enhanced performance of EV batteries is a major factor in the steady increase in electric vehicle sales. And better performance stems, in part, from recent developments in laser welding of dissimilar metals which increases efficiency by increasing energy storage, reducing size, and preserving reliability. It’s a fact that welding a less resistive metal to the standard stainless-steel terminal of a lithium ion battery can reduce resistance and improve battery efficiency. Traditional resistance spot welding, however, can’t effectively join highly-conductive dissimilar metals like copper and aluminum because the resultant intermetallic mix is brittle. But lasers CAN do the job with surprising results!
Today’s post is about using “teach mode,” a fairly standard software function that enables a laser operator to customize tool paths without having to write complex code. This feature aids the operator when there is significant part to part tolerance issues. Here’s an example of how teach mode works for a complex tool path:
Topics: laser welding
AMADA MIYACHI AMERICA strongly believes in serving the community and especially looks for ways to engage with students to encourage and develop the next generation of engineers. We have an active, thriving partnership with our local colleges and universities and provide technical internships to students in the engineering disciplines.
One fun event we recently hosted was a tour of the Monrovia, California facility by high school students from the San Gabriel Valley Economic Partnership. The partnership includes an education and workforce development initiative focused on a regional consortium of the Duarte, Azusa, Charter Oaks, and Monrovia school districts.
Topics: community service
Successful manufacturers constantly look for ways to improve quality while reducing costs. That’s why many are looking beyond conventional spot welding technology for something to help them achieve their cost reduction goals. Resistance welding traditionally utilizes alternating current (AC); however, this technology has limitations in the control of the output energy. Resistance welding with direct current (DC) using inverter technology, however, dramatically improves weld process control through closed loop feedback. This provides a consistent output, in turn lowering scrap and increasing production yield.
Recently we heard from “Suit Bot Sammy” (aka Samantha Childers), a junior at Monrovia High School (Monrovia, California), thanking us for helping the Monrovia Robotics program with the FIRST Tech Challenge. This is a cool program in which teams of 10+ members in grades 7-12 are challenged to design, build, program, and operate robots to compete in a head-to-head challenge in an alliance format. FIRST Tech Challenge encourages student teams to meet with members of the scientific community, serve the community, and fundraise to meet their goals.
Topics: community service
Recently we had a great opportunity to help the next generation of engineers compete in Formula SAE® Electric, a collegiate competition to conceive, design, fabricate, develop, and compete with small, formula style electric vehicles. The event is sponsored by the Society of Automotive Engineers (SAE). Our foray into the fast-paced world began when a team from the University of Pennsylvania contacted us after seeing online papers we published on battery tab welding. The team has nearly 100 college students designing and building an electric vehicle, and was working on improvements to their car for next year’s competition.
Topics: battery pack welding
Application engineers are a funny breed. They get their kicks from solving real-life manufacturing challenges – and the thornier the better! They like to get up close and personal with an application and help those having trouble to find the right way to weld, mark, cut, bond or machine a part. They also get a great deal of satisfaction from fixing a process that is taking too much time and affecting output (and the bottom line), one that results in unnecessary scrap or one that is out of limits. If the solution doesn’t work out the first time, they stick with it until they develop a one that works.
Simply put, machine vision is the ability of a computer to “see” and process information about what it “sees;” a camera system is used to acquire an image, which is then processed and used to complete a task. For example, a seam between two parts can be located and laser welded together. The exact position of the seam may vary due to part stack up tolerances; if so, the vision system is used to adjust the welding tool path automatically to match the actual location of the parts.
Topics: machine vision
This fourth installment in our multi-part series exploring micro pulse arc welding (micro TIG welding) focuses on “Touch Start” technology, which requires much lower voltage than the standard DC start system. Low voltage operation means no high frequency noise emission.
This is the third entry in our multi-part series exploring micro pulse arc welding welding. Today we will cover troubleshooting – tips for improving your results when you’ve followed all the recommended setup tips and you’re still getting spurious results, inconsistencies, or part shrinkage.