AutomotiveVIRO WSM supports robust laser welding processes in battery production

More than 20 so-called gigafactories for the production of e-vehicle batteries are currently being planned in Europe. The local industry wants to grab its slice of the pie and build more robust, independent supply chains.

In the production of e-vehicles, the battery plays the leading role: on the one hand, it is currently the most expensive of all components. For another, it directly affects the performance, driving experience and durability of the vehicles. Flawless and durable batteries are therefore a key factor if European manufacturers want to maintain their dominance in the automotive market of the future.

But compared to combustion technology, European manufacturers still have relatively little experience with battery production. They are still struggling with quality problems in many places and need to become much more efficient - as quickly as possible.

In laser welding, for example, the most important joining process in battery production, there is still huge potential for optimization. Mainly lightweight materials are used in batteries and battery housings. Laser welding allows thin and small components to be joined precisely, at high speed. To leverage the technology, however, the processes must function reliably.

However, for technical reasons, the laser welding process cannot be visually inspected during operation. Defects are therefore only detected during a subsequent visual inspection of the workpieces: By then, further rejects have already been produced and the line must be stopped to search for the cause.

With VIRO WSM from VITRONIC, such expensive interruptions can be prevented. The inspection system monitors the welding process in real time by using a sensor to constantly measure several spectral ranges of light and heat emissions relevant for quality of weld seams in battery production. The system reports anomalies outside the tolerances - they indicate potential quality problems.

NOK parts can thus be immediately detected, automatically rejected and rewelded. Causes of defects can be identified and resolved more quickly before further defects are produced. All measurement data are documented and are available for quality audits as well as for data-supported process optimization.

Thus, VIRO WSM supports manufacturers in delivering batteries of consistently high quality. At the same time, robust automated processes have a direct positive impact on production volumes and costs, and thus on competitiveness.

The technology behind VIRO WSM has been tested and used for years. Leading manufacturers of batteries and components in Asia rely on it including companies such as LG Energy Solution, SK ON, Samsung SDI, and Hyundai Mobis.

The flexibility as well as the ease of use contributes to the success of the solution. VIRO WSM is compatible with any welding solution and requires hardly any space in the welding line. Therefore, it can be easily retrofitted. Commissioning takes only about a week.

VITRONIC will present the system for the European market for the first time at Battery Show Europe. The trade show will take place from May 23 to 25 in Stuttgart. Interested parties can visit VITRONIC in Hall 6 at Stand A60 or make an appointment in advance via the company's event page.