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Characterization of photodiodes for detection of variations in part-to-part gap and weld penetration depth during remote laser welding of copper-to-steel battery tab connectors
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Chianese, Giovanni, Franciosa, Pasquale, Nolte, Jonas, Ceglarek, Darek and Patalano, Stanislao (2021) Characterization of photodiodes for detection of variations in part-to-part gap and weld penetration depth during remote laser welding of copper-to-steel battery tab connectors. In: 16th International Manufacturing Science and Engineering Conference, Virtual, Online, 21-25 Jun 2020. Published in: Proceedings of the ASME 2021 : 16th International Manufacturing Science and Engineering Conference MSEC2021
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WRAP-characterization-photodiodes-detection-variations-part-to-part-gap-weld-penetration-depth-during-remote-laser-welding-copper-to-steel-battery-tab-connectors-2021.pdf - Accepted Version - Requires a PDF viewer. Download (1803Kb) | Preview |
Abstract
This paper addresses sensor characterization to detect variations in part-to-part gap and weld penetration depth using photodiode-based signals during Remote Laser Welding (RLW) of battery tab connectors. Photodiode-based monitoring has been implemented largely for structural welds due to its relatively low cost and ease of automation. However, research in sensor characterization, monitoring and diagnosis of weld defects during joining of battery tab connectors is at an infancy and results are inconclusive. Motivated by the high variability during the welding process of dissimilar metallic thin foils, this paper aims to characterize the signals generated by a photodiode-based sensor to determine whether variations in weld quality can be isolated and diagnosed. Photodiode-based signals were collected during RLW of copper-to-steel thin-foil lap joint (Ni-plated copper 300 μm to Ni-plated steel 300 μm). The presented methodology is based on the evaluation of the energy intensity and scatter level of the signals. The energy intensity gives information about the amount of radiation emitted during the welding process, and the scatter level is associated with the accumulated and un-controlled variations. Findings indicated that part-to-part gap variations can be diagnosed by observing the step-change in the plasma signal, with no significant contribution given by the back-reflection. Results further suggested that over-penetration corresponds to significant increment of the scatter level in the sensor signals. Opportunities for automatic isolation and diagnosis of defective welds based on supervised machine learning are discussed.
Item Type: | Conference Item (Paper) | |||||||||||||||
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Subjects: | T Technology > TK Electrical engineering. Electronics Nuclear engineering T Technology > TL Motor vehicles. Aeronautics. Astronautics |
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Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | |||||||||||||||
Library of Congress Subject Headings (LCSH): | Electric vehicles -- Batteries, Hybrid electric vehicles -- Batteries, Laser welding, Manufacturing processes -- Automation, Electric batteries -- Design and construction, Photodiodes | |||||||||||||||
Journal or Publication Title: | Proceedings of the ASME 2021 : 16th International Manufacturing Science and Engineering Conference MSEC2021 | |||||||||||||||
Publisher: | ASME | |||||||||||||||
Official Date: | 2021 | |||||||||||||||
Dates: |
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Status: | Peer Reviewed | |||||||||||||||
Publication Status: | Published | |||||||||||||||
Access rights to Published version: | Restricted or Subscription Access | |||||||||||||||
Date of first compliant deposit: | 12 July 2022 | |||||||||||||||
Date of first compliant Open Access: | 12 July 2022 | |||||||||||||||
RIOXX Funder/Project Grant: |
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Conference Paper Type: | Paper | |||||||||||||||
Title of Event: | 16th International Manufacturing Science and Engineering Conference | |||||||||||||||
Type of Event: | Conference | |||||||||||||||
Location of Event: | Virtual, Online | |||||||||||||||
Date(s) of Event: | 21-25 Jun 2020 | |||||||||||||||
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