Market Application Background
With the robust growth of China's new energy vehicle market, the domestic laser welding industry has rapidly emerged. Laser welding is widely used in the mid- and late-stage production processes of power batteries, including key processes such as welding battery module connecting pieces, welding explosion-proof valves, and welding electrode tabs.
The welding quality of power batteries in new energy vehicles is directly related to the reliability and service life of battery connections. Therefore, optimizing the problems existing in the traditional laser welding process has become crucial.
Problems with traditional laser welding:
When performing high-speed welding of complex trajectories, traditional lead screw and guide servo motor systems can cause problems such as over-processing and excessive weld depth-to-width ratio when the welding head is on a complex machining trajectory due to the high-speed operation of the mechanism. Especially at chamfers, the movement speed of the welding head will decrease, resulting in unstable welding speed, uneven distribution of laser processing energy density, and affecting the welding effect.
Positive motion technology solutions:
Against this backdrop, the ZMC408SCAN-V2 open-source laser galvanometer motion controller, based on positive motion technology, stands out. With its advantages of high efficiency and stability, ease of use, and integration of galvanometer, laser, and axis control, it has become the preferred choice for new energy vehicle manufacturers. It also supports high-speed PSO, PWM, and speed look-ahead functions, ensuring smooth laser processing trajectories and improving product quality and production capacity.
When used in high-power laser galvanometer systems for welding flexible connectors, the ZMC408SCAN-V2 can perform arc trajectory welding at a speed of 200-300 milliseconds per second. It can even be used in some modules for complex laser processing trajectories such as S-shapes and spiral curves, perfectly avoiding the problems of traditional systems.
01. Application of Open-Type Laser Galvanometer Motion Controller in Welding of Connecting Pieces for Power Battery Modules
Pain points of traditional laser welding solutions
●Standard laser system software is complex to operate, making it difficult to respond to non-standard customization needs on the production line;
●The motion control card and laser galvanometer card are controlled independently, making application software development more difficult;
● The speed of laser welding on servo platforms is limited, and the effect of high-speed processing of complex trajectories is not good.
Positive motion technology solutions
Scheme Design
Application Demonstration Cases
It adopts a teaching-editing method to automatically generate machining trajectories and supports welding process curves such as spirals and involutes.
1. Operating Procedures:
①
Configure the corresponding laser parameters according to the laser type and wiring; ②
Correct the galvanometer distortion using calibration software and save the calibration parameters; ③
Edit the corresponding welding trajectory and process according to the size of the product weld; ④
Set the processing speed and delay process parameters; ⑤
Trigger the marking, observe and inspect the welding effect, and adjust the parameters.
2. Welding effect diagram:
Advantages of the solution
● Interpolation between the galvanometer axis and the servo axis;
● Flexible laser power adjustment: Laser parameters can be freely adjusted according to laser type and wiring configuration;
● Processing speed and delay parameters can be set to precisely control the welding process and adapt to different materials and welding requirements;
●Supports multiple development methods such as C++ and C#, and provides a dedicated laser function library and application examples to help equipment system vendors quickly develop and deliver solutions;
● Spiral trajectory welding function: By rotating the light spot at high speed along the welding direction, different weld depth-to-width ratios can be achieved without changing the external light path conditions.
Core process of the solution
1. Spiral trajectory:
In high-energy beam welding, a large weld depth-to-width ratio is a characteristic of laser welding. When a large weld depth-to-width ratio is undesirable, such as when welding battery module connectors, a wider weld (to increase the current-carrying area) and a reduced weld depth (to use thinner battery terminals and obtain more cell space) are typically required. Helical trajectory welding is used, where the laser spot rotates at high speed along the welding direction. This allows for different weld depth-to-width ratios without changing the external optical path conditions.
2. Laser power control:
Power control (analog voltage, PWM modulation) is crucial in laser welding, as its quality directly affects the processing results. Power control in laser processing includes two aspects: power control and synchronous control of power and motion. Power control refers to generating appropriate control signals to control the laser output power as required, while synchronous control of power and motion refers to ensuring that the power closely follows changes in processing position or speed to guarantee consistent processing quality.
02. Introduction to ZMC408SCAN-V2 Open Laser Galvanometer Motion Controller
The stand-alone laser galvanometer motion controller integrates laser control, galvanometer control, and bus axis/pulse axis control, helping you achieve a highly efficient and precise EtherCAT bus motion control + laser galvanometer solution.
●Optional 6-64 axis motion control (pulse + EtherCAT bus);
● Two laser galvanometer interfaces with feedback, one dedicated laser power supply interface for LASER and one dedicated laser interface for FIBER;
●Supports 1D/2D/3D PSO functions, enabling visual imaging, precision dispensing, and laser energy control;
● The integration of laser galvanometer control and motion control allows for the flexible construction of laser processing systems with multi-axis linkage and other methods;
● Multi-dimensional position synchronous output (PSO), onboard 24 general-purpose inputs and 20 general-purpose outputs, including 4 high-speed color mark latches, 4 PSOs and 8 PWM outputs.
03. Summary of the Plan
The ZMC408SCAN-V2 open-type laser galvanometer motion controller is a key component in the welding of connecting pieces for power battery modules in new energy vehicles. In the rapidly growing domestic new energy vehicle market, this technology provides a targeted solution to overcome the limitations of traditional welding methods. It automatically generates welding trajectories through a teach-and-edit approach, supports multiple development methods and a dedicated laser function library, helping equipment system vendors develop and deliver products more quickly. The ZMC408SCAN-V2 supports the control functions required for various laser welding processes, overcoming the problems of traditional laser welding systems and improving welding quality and efficiency.
