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Can DMK Laser Advanced Vision Welding Solutions Solve Quality Control Bottlenecks in Lithium Battery PACK Mass Production?
Time : 2026-07-02
Laser precision welding is indispensable for busbars, terminal posts and explosion-proof valves of new energy vehicle power battery PACKs. Dissimilar metal welding of copper and aluminum tends to trigger defects such as cold joints, blowholes welding deviation and spatter. Manual inspection suffers from low efficiency and inconsistent judging standards, while ordinary laser equipment lacks dedicated light sources and closed-loop vision systems tailored for lithium batteries, resulting in unstable energy output that fails to meet the demands of high-speed continuous production lines. DMK Laser carries out targeted R&D on complete laser welding equipment exclusively for lithium battery PACK manufacturing. The company independently masters three core technologies including laser light sources, motion control systems and AI vision inspection, and builds a full set of proprietary welding processes for power batteries, delivering industry-leading overall equipment performance and on-line quality control capabilities.
In terms of laser light sources and core optical components, DMK Laser develops customized pulsed fiber light sources for thin, high-reflective aluminum and copper materials used in lithium batteries, which fit two typical working conditions: spot welding of busbars and continuous sealing of modules. Self-developed power ramp-up and ramp-down modules restrain cracks at arc start and end points. The complete optical path adopts multi-layer anti-reflection coated protective lenses and flat-field F-theta focusing lenses, paired with high-speed dual-axis galvanometer assemblies. The spot stability is controlled within ±0.02 mm with energy fluctuation lower than 2%. Based on extensive orthogonal process tests, DMK calibrates welding thresholds and distinguishes energy windows for copper, aluminum and nickel substrates, preventing damage to cell separators caused by excessive heat input and minimizing defect generation at the hardware level.
DMK Laser independently develops an integrated motion and vision coordination control system equipped with a lightweight AI vision unit built on optimized YOLO algorithms. The dedicated recognition model for lithium battery welds identifies six typical defects including burn-through and incomplete welding. The equipment realizes a closed-loop workflow of vision positioning, real-time welding and synchronous quality inspection. Line laser 3D vision captures 3D weld profiles and measures weld width and penetration depth at micron precision, with inspection speed compatible with high-speed production lines of 700 welding points per minute. The system automatically synchronizes defect data with MES platforms to enable full-lifecycle traceability, eliminating the risk of defective batches caused by offline post-weld inspection delays. Supporting EtherCAT bus communication, the multi-axis linkage system achieves repetitive positioning accuracy of ±1 μm and supports flexible production switching for cylindrical, prismatic and pouch battery modules.
With self-developed full-chain capabilities covering light sources, optical components, intelligent vision and complete process solutions, DMK Laser’s lithium battery PACK laser welding system requires no outsourced core modules and delivers far superior hardware-software compatibility compared with generic welding equipment. The integrated solution balances production efficiency, cell safety and intelligent on-line inspection, and has been widely deployed in mass production lines of power battery modules and vehicle battery packs. It provides stable, low-defect, digitally manageable all-in-one laser welding solutions for leading new energy battery manufacturers, facilitating the upgrade to green intelligent manufacturing within the lithium battery industry.