LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
TRUMPF Laser Technology Center
Rick Davis
Fort Lauderdale, Florida, 3/21/2017
LASER APPLICATIONS IN BATTERY PRODUCTIONInternational Battery Seminar
Head of Automotive Sales - North America
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LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
Electrified powertrain means challenges – and opportunities
for “old“ and “new“ players in the automotive market
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big investments in manufacturing technologies worldwide
fast growing market for electrified cars worldwide
new car manufacturers worldwidebig changes in value-added chain
Reuters.com; 01.09.2016
Detroit Free Press; 14.09.2016
Forbes; 15.09.2016
Gogoro-Scooter
E-Mobilität online; 07.09.2016
handelsblatt; 26.08.2016
green Car Report; 31.03.2016
ZF expects to adjust to early breakthrough of electro-mobility and gearbox production
The core brand has been suffering from its suspicious weakness for years. A $Bil tax scandal surrounding eleven million diesel vehicles shook the world. Electro-mobility is certainty a factor moving forward.
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
CARS – made by laser
3
Powertrain
Lightweight Design
Cutting and Hotforming
Electrification
Interior and assembly
Cutting hotforming parts Softening Inductive heating 3D cutting tubes / sheets
Battery Cell/Module/Pack Electric drives Fuel cells Electronic
Day/Night designsMarking Drilling Surface treatment
Gear welding Clutches Differentials Shifting forks
Flange reduction Linear sheet metal design Integrated functions New materials
Remote applications Laser welding and brazing
Body Shop car body
electrified powertrain
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
Not including suspension and steering system
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Components for electrified powertrain
frame
BMS(battery management system)
cooling system
cell module
electric drive
transmission
electronic
battery pack
powertrain
electrified powertrain
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 5
Components for electrified powertrain
frame
BMS(battery management system)
cooling system
cell module
electric drive
transmission
electronic
battery pack
powertrain
electrified powertrain
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 6
Production steps – cell manufacturing
• TruFiber
• TruPulse
• TruDisk
Opt
ics
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruPulse
• TruDisk
• TruFiber
• TruDisk
• TruDisk
• TruMark
Coating and compressing
Pro
duct
ion
Ste
p
or Sheet Cutting
Cutting
Slitting Tap welding Packaging Filling Assembling
Source: Breyer GmbH
Source: newlong.com
Lase
r so
urce
Cutting Welding Welding Welding Welding,Marking
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 7
Production steps – cell manufacturing
• TruFiber
• TruPulse
• TruDisk
Opt
ics
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruPulse
• TruDisk
• TruFiber
• TruDisk
• TruDisk
• TruMark
Coating and compressing
Pro
duct
ion
Ste
p
or Sheet Cutting
Cutting
Slitting Tap welding Packaging Filling Assembling
Source: Breyer GmbH
Source: newlong.com
Lase
r so
urce
Cutting Welding Welding Welding Welding,Marking
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 8
Cutting of electrode foils
Cathode
Anode
Application • cutting of electrode foil or flag
Material • battery electrode Cu/Al single- /two-sided coating
Requirements
• burr free cutting edge• no particles• no delamination• no crack• high productivity
Laser• TruFiber• TruMicro• TruDisk
CustomerValue
• flexibility in cutting geometry
• cutting without dross• low heating zone• less quality control effort
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 9
Production steps – cell manufacturing
• TruFiber
• TruPulse
• TruDisk
Opt
ics
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruPulse
• TruDisk
• TruFiber
• TruDisk
• TruDisk
• TruMark
Coating and compressing
Pro
duct
ion
Ste
p
or Sheet Cutting
Cutting
Slitting Tap welding Packaging Filling Assembling
Source: Breyer GmbH
Source: newlong.com
Lase
r so
urce
Cutting Welding Welding Welding Welding,Marking
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 10
Tap Welding
Application • welding of contact pins
Material • Cu-Al, app. 0,3 mm
Requirements
• joining of material combination
• electrical contact• mechanical strength
Laser • TruDisk
CustomerValue
• flexibility in welding geometry
• no porosity, no cracks• clean working process• little space requirements• no mechanical stress
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 11
Production steps – cell manufacturing
• TruFiber
• TruPulse
• TruDisk
Opt
ics
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruPulse
• TruDisk
• TruFiber
• TruDisk
• TruDisk
• TruMark
Coating and compressing
Pro
duct
ion
Ste
p
or Sheet Cutting
Cutting
Slitting Tap welding Packaging Filling Assembling
Source: Breyer GmbH
Source: newlong.com
Lase
r so
urce
Cutting Welding Welding Welding Welding,Marking
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 12
Welding battery housing
Application • welding of battery housing
Material • Al; 0,6 - 1 mm
Requirements • gas-tight sealing• no splatter
Laser • TruDisk
Scanner • PFO (Programmable Focus Optics)
CustomerValue
• high productivity• low heat input• no distortion• no mechanical load
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 13
Laser applications in E-Mobility
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 14
Production steps – cell manufacturing
• TruFiber
• TruPulse
• TruDisk
Opt
ics
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruMicro
• TruDisk
• TruFiber
• TruPulse
• TruDisk
• TruFiber
• TruDisk
• TruDisk
• TruMark
Coating and compressing
Pro
duct
ion
Ste
p
or Sheet Cutting
Cutting
Slitting Tap welding Packaging Filling Assembling
Source: Breyer GmbH
Source: newlong.com
Lase
r so
urce
Cutting Welding Welding Welding Welding,Marking
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 15
Welding of bus bar
Application • welding of bus bar
Material • Cu-Cu; 0,3 mm – 1 mm• Al-Al; 0,3 mm – 1 mm
Requirements • electrical contact• mechanical strength
Laser • TruDisk
Scanner • PFO (Programmable Focus Optics)
CustomerValue
• flexibility in cutting geometry
• no splittings• no splatter
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
Welding of electronic parts / welding copper with green laser
Uniformity of spot welds on different surface conditions @ 515 nm
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• Weld quality does not depend on surface quality of copper• High accuracy in weld depth – no influence on parts beneath weld area• Spatter free welds – especially important for electronic parts
Laser is the right tool for welding electric parts (e.g. battery, electric drives, electronic devices) with high efficiency and high quality
etched with acid
rough surface
original surface
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
Green pulsed laser system
Peak Power 4 kW; average power 750 W; λ 515 nm
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LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017 18
Marking of battery cell
Application• Marking of Al and Cu• Text, Bar-Code, Datamatrix-
Code
Material • Cu, Al; 0,2 – 0,3 mm
Requirements
• Enduring readability of the code
• High flexibility regarding content, e. g. serial number
• Low influence of material
Laser • TruMark
Scanner • App. 1 min for data matrix code
CustomerValue
• Flexibility of marking geometry
• Flexibility of material
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/2017
CARS – made by laser
Laser Tools by TRUMPF
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Powertrain
Lightweight Design
Cutting and Hotforming
Electrification
Interior and assembly
Cutting hotforming parts Softening Inductive heating 3D cutting tubes / sheets
Battery Cell/Module/Pack Electric drives Fuel cells Electronic
Day/Night designsMarking Drilling Surface treatment
Gear welding Clutches Differentials Shifting forks
Flange reduction Linear sheet metal design Integrated functions New materials
Remote applications Laser welding and brazing
Body Shop car body
electrified powertrain
LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis 3/21/20173/21/2017LASER APPLICATIONS IN BATTERY PRODUCTION, Rick Davis
TRUMPF Laser Technology Center
Rick DavisHead of Automotive Sales - North America(734) [email protected]
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