Online process monitoring with near-zero misdetection for ultrasonic welding of lithium-ion batteries: An integration of univariate and multivariate methods

Weihong Guo, Chenhui Shao, Tae Hyung Kim, S. Jack Hu, Jionghua Jin, J. Patrick Spicer, Hui Wang

Research output: Contribution to journalArticlepeer-review

23 Scopus citations

Abstract

Ultrasonic metal welding is used for joining lithium-ion batteries of electric vehicles. The monitoring of battery joining processes requires near-zero misdetection in order to prevent any battery joints with a low quality connection going into the downstream assembly. The conventional control chart techniques widely used in many process monitoring systems were designed based on a pre-specified false alarm rate. To ensure weld quality and reduce manual inspection at the same time, a near-zero misdetection rate is desired foremost while achieving a low false alarm rate. A monitoring algorithm targeting near-zero misdetection is developed in this article by integrating univariate control charts and the Mahalanobis distance approach. The proposed algorithm is capable of monitoring non-normal multivariate observations with flexible control limits to achieve a near-zero misdetection rate while keeping a low false alarm rate. By implementing this algorithm on the ultrasonic welding process of battery manufacturing, the developed algorithm proves to be effective in achieving near-zero misdetection in process monitoring to ensure battery weld quality. The developed algorithm also shows great potential for monitoring other processes that target at near-zero misdetection.

Original languageEnglish (US)
Pages (from-to)141-150
Number of pages10
JournalJournal of Manufacturing Systems
Volume38
DOIs
StatePublished - 2016

All Science Journal Classification (ASJC) codes

  • Software
  • Control and Systems Engineering
  • Hardware and Architecture
  • Industrial and Manufacturing Engineering

Keywords

  • Lithium-ion battery
  • Mahalanobis distance
  • Near-zero misdetection
  • Process monitoring
  • Shewhart control chart
  • Ultrasonic metal welding

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