Characterization of ultrasonic metal welding by correlating online sensor signals with weld attributes

S. Shawn Lee, Chenhui Shao, Tae Hyung Kim, S. Jack Hu, Elijah Kannatey-Asibu, Wayne W. Cai, J. Patrick Spicer, Jeffrey A. Abell

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Online process monitoring in ultrasonic welding of automotive lithium-ion batteries is essential for robust and reliable battery pack assembly. Effective quality monitoring algorithms have been developed to identify out of control parts by applying purely statistical classification methods. However, such methods do not provide the deep physical understanding of the manufacturing process that is necessary to provide diagnostic capability when the process is out of control. The purpose of this study is to determine the physical correlation between ultrasonic welding signal features and the ultrasonic welding process conditions and ultimately joint performance. A deep understanding in these relationships will enable a significant reduction in production launch time and cost, improve process design for ultrasonic welding, and reduce operational downtime through advanced diagnostic methods. In this study, the fundamental physics behind the ultrasonic welding process is investigated using two process signals, weld power and horn displacement. Several online features are identified by examining those signals and their variations under abnormal process conditions. The joint quality is predicted by correlating such online features to weld attributes such as bond density and post-weld thickness that directly impact the weld performance. This study provides a guideline for feature selection and advanced diagnostics to achieve a reliable online quality monitoring system in ultrasonic metal welding.

Original languageEnglish (US)
Title of host publicationASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
PublisherWeb Portal ASME (American Society of Mechanical Engineers)
ISBN (Electronic)9780791845813
DOIs
StatePublished - Jan 1 2014
Externally publishedYes
EventASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference - Detroit, United States
Duration: Jun 9 2014Jun 13 2014

Publication series

NameASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
Volume2

Other

OtherASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
Country/TerritoryUnited States
CityDetroit
Period6/9/146/13/14

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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