Tool wear monitoring for ultrasonic metal welding of lithium-ion batteries

Chenhui Shao, Tae Hyung Kim, S. Jack Hu, Jionghua Judy Jin, Jeffrey A. Abell, J. Patrick Spicer

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

Abstract

This paper presents a tool wear monitoring framework for ultrasonic metal welding which has been used for lithium-ion battery manufacturing. Tool wear has a significant impact on joining quality. In addition, tool replacement, including horns and anvils, constitutes an important part of production costs. Therefore, a tool condition monitoring (TCM) system is highly desirable for ultrasonic metal welding. However, it is very challenging to develop a TCM system due to the complexity of tool surface geometry and a lack of thorough understanding on the wear mechanism. Here, we first characterize tool wear progression by comparing surface measurements obtained at different stages of tool wear, and then develop a tool condition classification algorithm to identify the state of wear. The developed algorithm is validated using tool measurement data from a battery plant.

Original languageEnglish (US)
Title of host publicationMaterials; Biomanufacturing; Properties, Applications and Systems; Sustainable Manufacturing
PublisherAmerican Society of Mechanical Engineers
ISBN (Electronic)9780791856833
DOIs
StatePublished - Jan 1 2015
Externally publishedYes
EventASME 2015 International Manufacturing Science and Engineering Conference, MSEC 2015 - Charlotte, United States
Duration: Jun 8 2015Jun 12 2015

Publication series

NameASME 2015 International Manufacturing Science and Engineering Conference, MSEC 2015
Volume2

Other

OtherASME 2015 International Manufacturing Science and Engineering Conference, MSEC 2015
CountryUnited States
CityCharlotte
Period6/8/156/12/15

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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