Ultrasonic welding and laser welding have emerged as prominent technologies for making busbar connections in EV battery modules. While both technologies can be automated and offer the quality and precision needed for battery manufacturing, there are important differences to consider
Lasers are ideal for industrial automation. Not only do they have the potential to increase productivity and repeatability, but they also possess key characteristics that facilitate automation. Examples include remote capabilities, low maintenance, almost no consumables and waste products, and minimal dust.
The battery is the most expensive part in an electric car, so a reliable manufacturing process is important to prevent costly defects. Electric vehicle batteries are also in high demand, which puts pressure on manufacturers to maximize production without compromising quality. As a result, robot automation is almost everywhere during battery manufacturing.
With the rapid growth of EVs in the automotive industry, battery welding has become an important challenge to keep up with demanding production requirements. At Laserax, we have developed a laser welding cell that addresses these challenges.
Laser surface treatments can be used on almost all types of metals, including carbon steel, cast iron, aluminum, molybdenum, and magnesium. They can remove contaminants and coatings (laser cleaning), modify the surface roughness (laser texturing), harden surfaces (laser hardening), and add materials to surfaces to improve surface properties (laser cladding).
Not so long ago, CO2 lasers were the only lasers available for laser welding—and they had important limitations for automation. The arrival of fiber laser technology has drastically changed the landscape, offering high speed, high precision, low maintenance, and rock-solid stability through movements and vibrations.
Laser ablation occurs when a laser beam removes material from a localized area. Used in various industrial applications, this process can create permanent marks (laser marking), remove contaminants and coatings from surfaces (laser cleaning), modify a part’s roughness (laser texturing), cut through a surface (laser cutting) and much more.
Industrial laser welding of copper is in growing demand. One reason is the electrification of the automotive industry, where various electrical components are made of copper to improve electrical and thermal conductivity.
Lasers and robotics are both used by manufacturers for their speed and precision. It’s natural that these two technologies frequently work hand in hand in production lines to perform laser welding.
We’ve reached a time where laser welding is not only viable for high-volume production lines, but also for all types of manufacturers. With laser welding being so accessible, now is a good time to explore this proven process that promises precision, speed, and cost effectiveness.
To apply adhesives, manufacturers use a method called adhesive bonding. Due to its many benefits, it is widely used to replace welds and mechanical fasteners.
There are countless ways to blast a surface due to the variety of abrasive materials. In today’s industrial environments, grit blasting is often chosen because it is low cost and effective when cleaning several types of large surfaces, including metals, plastics, and ceramics.
