軟包電池模組焊接前折彎結構設計與導入平整度控制之研究

Abstract

隨著電動車與儲能裝置需求提升，具備輕量化與高能量密度特性的軟包電池模組於產業應用日益廣泛。然而，其鋁極耳結構柔軟，容易在預處理階段產生形變與貼合不良，導致雷射焊接品質不穩，進而影響導電與結構可靠性。實務上，部分廠商仍倚賴人工對位與按壓，缺乏有效自動化對應方案。為解決上述問題，本研究提出一套整合式預處理機構，涵蓋旋轉式折彎模組與閉迴路滾壓系統。藉由有限元素模擬與成形力分析，驗證旋轉式折彎（Rotary bending）可有效降低回彈力需求，成形力僅為擦拭彎曲（Wipe bending）的50.2%。滾壓控制則結合壓力與距離感測，透過模糊控制器建構輸入-輸出對應規則曲面，實現查表式閉迴路控制。最終系統具備即時響應與彈性調控能力，可提升貼合品質與製程穩定性，提供未來自動化應用之設計依據。

As the demand for electric vehicles and energy storage systems continues to rise, pouch-type lithium battery modules, known for their lightweight structure and high energy density have become increasingly prevalent. However, due to the flexible and thin nature of aluminum tabs, issues such as deformation and misalignment frequently occur during pre-welding processing. These defects often result in weak or failed in laser welding, compromising electrical conductivity and structural integrity. In current industrial, the lack of automation has made consistent tab-busbar bonding a key challenge. This research proposes an integrated pre-welding mechanism combining a rotary tab-bending module and a closed-loop rolling system to enhance the bonding quality between tabs and busbars. Finite element simulations and forming force evaluations indicate that the rotary bending method reduces the forming force to just 19.5% of that required in conventional wipe bending, demonstrating its suitability for aluminum tab forming. The rolling module incorporates pressure and distance sensing, with a fuzzy logic controller developed to adaptively regulate the pressing process. A rule-based surface was constructed and converted into a lookup table for real-time control implementation. The developed system provides reliable tab positioning and pressure regulation capabilities, contributing to improved bonding uniformity and welding consistency. This research offers a practical reference for the advancement of automation in pouch cell module assembly.