The European industry is working at full speed to set up its own production chains for e-vehicle batteries: more than 20 gigafactories are currently being planned. One of the most important processes here is laser welding to precisely join lightweight materials and small components. For quality and costs to be right, however, the processes must function stably. Deviations and errors must be detected and eliminated immediately before rejects are produced and the line has to be stopped.
This is exactly what the VIRO WSM inspection system does: it monitors the welding process in real time and reports anomalies outside the tolerances. As a result, NOK parts can be immediately identified and automatically reworked; the causes of defects can be quickly found and eliminated. The system has been used for years by leading companies in battery production, primarily in Asia, and has recently also become available for European manufacturers.
Defective welds can get vehicle manufacturers into serious trouble. In the worst case, lawsuits and recalls are imminent, which can cost millions of dollars and a good reputation. Therefore, zero-defect tolerance applies to safety-relevant parts. No part with a defective weld, for example on axles, bodywork or batteries, may be delivered. However, manual testing is expensive and error-prone.
This is why OEMs and Tier 1 suppliers have been relying on VIRO WSI for decades: an optical inspection system that inspects every single weld seam fully automatically and detects all relevant defects from 0.1 millimeter with 100% reliability. Since the inspection takes place directly in the welding line, it is possible to quickly intervene in the upstream welding process. This consistently reduces defects, optimizes processes, and avoids downtime, rework, and rejects.
One area of application for VIRO WSI that is currently in particularly high demand is the automated quality inspection of battery trays - the central element in the body of electric vehicles. At this component, the system can not only inspect the more than 100 individual weld seams. In the same way, it detects weld spatter or other contaminants on surfaces, as well as missing or ill-fitting screw connections. The commissioning of VIRO WSI is comparatively quick - one of the reasons for the system's success.
Guaranteeing high quality and zero defects while working economically: these two goals are difficult to reconcile. The solution: permanent process optimization. However, manufacturers are often slow to make progress with the processes involved in welding and weld seam testing. Many optimization tasks are performed manually, based on experience and trials.
With the Weldloop software, optimization can be accelerated significantly. It allows the data from the weld seam inspection to be linked with the data from the welding process, evaluated and visually displayed. Causes of deviations and defects can thus be found and eliminated quickly, with minimal downtime. Conducting long-term analyses, further optimization potential can be uncovered.
All three solutions support vehicle manufacturers and suppliers in setting up efficient, highly automated production. They enable defect-free products that can hold their own in global competition. Learn more about VITRONIC's innovations at the SCHWEISSEN & SCHNEIDEN trade show, September 11-15, 2023 in Essen, Germany. Visit us in hall 3 at booth 3D49. Please feel free to arrange a personal meeting in advance.