AEi developed a modified version of its VGLase vision guided laser tool to precisely and accurately weld and laser mark casings for very high power density batteries. Integrity of the laser weld for this application is extremely important since these batteries are for applications that include deep sea and outer space deployment and product quality and reliability is key.

Platforms & Products:

  • FlexAuto
  • Vision Guided Laser Tool (VGLase)

Processes & Tools:

  • Precision Motion
  • Machine Vision Guided Automation
  • Laser Processing

Application Requirements:

  • Vision guided motion
  • Automated component load and unload
  • Multi-axis motion for helical weld trajectories
  • YAG laser welding
  • Laser safety interlocks
  • Laser marking using galvanometer driven beam

The battery housings to be welded and marked contain a fill material that is explosive if it comes in contact with water, making a perfect hermetic seal for the seam weld essential. The weld path had to be adjusted automatically to compensate for component part variations to execute the required welds.

AEi used multiple vision cameras and the FlexAuto machine vision and motion control software used machine vision analysis of weld zone images to dynamically adjust the weld trajectory path to precisely follow the seam at the end of the casing. The image analysis algorithms incorporated user configurable offsets and thresholds to allow for tuning the beam trajectory for each different casing to be welded. Once the weld seam path was determined, the FlexAuto software executed the automated laser welding. When welding was completed the station automatically moved the casing to the laser marking station, executed the marking, and then moved the completed casing to an out feed tray.