Abstract: A system includes a memory storing a dimensionally aware model generated based on a training set and guided by feature dimensions and instructions for execution a processor. The instructions include, in response to receiving a set of data from a user device, identifying a set of features from the set of data and applying the dimensionally aware model to the set of features by implementing a boundary representation.

Abstract: A method for identifying a cell quality during cell formation includes: conducting a beginning of life cycling following an initial cell formation charge of multiple cells; collecting and preprocessing a discharge data set generated by one of the multiple cells during the beginning of life cycling; calculating a statistical variance from the discharge data set identifying an estimated probability of meeting a target cell usage time; and projecting a life span of the multiple cells.

Abstract: A method of analyzing the quality of a battery cell includes performing a high-throughput quality check on the battery cell with a quality control system, assessing a quality score to the battery cell, with quality score identifying the battery cell as low-quality or high-quality, and performing a comprehensive quality check on the battery cell if identified as low-quality. The method further includes assessing an enhanced quality score to the battery cell superseding the quality score of the quality control system identifying the battery cell as confirmed low-quality or confirmed high-quality and providing revised production instructions for manufacturing successive battery cells if confirmed low-quality.

Abstract: A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.

Abstract: Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements.

Abstract: A method of analyzing the quality of a battery cell includes performing a high-throughput quality check on the battery cell with a quality control system, assessing a quality score to the battery cell, with quality score identifying the battery cell as low-quality or high-quality, and performing a comprehensive quality check on the battery cell if identified as low-quality. The method further includes assessing an enhanced quality score to the battery cell superseding the quality score of the quality control system identifying the battery cell as confirmed low-quality or confirmed high-quality and providing revised production instructions for manufacturing successive battery cells if confirmed low-quality.

Abstract: A method for identifying a cell quality during cell formation includes: conducting a beginning of life cycling following an initial cell formation charge of multiple cells; collecting and preprocessing a discharge data set generated by one of the multiple cells during the beginning of life cycling; calculating a statistical variance from the discharge data set identifying an estimated probability of meeting a target cell usage time; and projecting a life span of the multiple cells.

Abstract: A system includes at least one processor and a memory. The memory stores a dimensionally aware model generated based on a training set and guided by feature dimensions and instructions for execution by the at least one processor. The instructions include, in response to receiving a set of data from a user device, identifying a set of features from the set of data and applying the dimensionally aware model to the set of features by implementing a boundary representation. The instructions include classifying the set of features as acceptable in response to the implementation of the boundary representation indicating the set of features are outside the boundary representation, classifying the set of features as unacceptable in response to the implementation of the boundary representation indicating the set of features are inside the boundary representation, and generating, for display on the user device, an alert based on the classification.

Abstract: A welding block for a welding system secures together first and second components of a workpiece for a motor vehicle to reduce distortion of the first and second components during a welding process. The welding block includes a jig mechanism that has a proximal surface for receiving a load from an arm of the welding system. The jig mechanism further includes a distal surface for engaging the first component and securing the first and second components to one another during the welding process. The jig mechanism defines a passage, such that heat flows from the distal surface to a coolant flowing through the passage. The welding block further includes a sensor coupled to the jig mechanism for detecting a measured variable associated with at least one of the first and second components.

Abstract: A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.

Abstract: A method and a test fixture for evaluating a battery cell are described, wherein the battery cell is composed of a cell body having a plurality of electrode foils that are joined to both a positive terminal and a negative terminal at weld junctions. The method includes retaining the cell body of the battery cell in a first clamping device and gripping one of the positive and negative terminals in a terminal gripper. A dynamic stress end effector coupled to the terminal gripper is employed to apply a vibrational excitation load to the one of the positive and negative terminals. Impedance between the positive terminal and the negative terminal is monitored via a controller, and integrity of the weld junction of the one of the positive and negative terminals is evaluated based upon the impedance.

Abstract: A method and an apparatus for evaluating a battery cell. The battery cell may include a hermetically sealed outer casing, a plurality of electrically conductive components enclosed within the outer casing, an electrically conductive terminal having a proximal end that extends within the outer casing and a distal end that extends in a longitudinal direction relative to the battery cell outside the outer casing, and a solid electrical and mechanical joint formed between one or more of the electrically conductive components and the proximal end of the electrically conductive terminal. Evaluation of the battery cell may include measuring the impedance of the battery cell while applying a longitudinal pulling force or a transverse bending force to the electrically conductive terminal and the solid electrical and mechanical joint.

Abstract: A number of variations may involve a method that may include providing a non-conductive layer. A conductive layer may be provided overlying the non-conductive layer with the conductive layer to form a sensor device. An opposition to electrical current through the conductive layer may be monitored. The location of a status of the non-conductive layer or of the conductive layer may be determined through a change in the opposition.

Abstract: A vehicle-battery system including a battery cell and a micro heat exchanger. The micro heat exchanger includes at least one fluid tube positioned in direct contact with the battery cell. The fluid tube comprises a heat-transfer tube section positioned between a fluid tube entrance and exit and in direct contact with the battery cell. The fluid tube is configured to receive a heat-transfer fluid, such a nanofluid, and channel the heat-transfer fluid through the heat-transfer tube section, to the fluid tube exit. The heat-transfer fluid is configured to cool or heat the battery cell when, in operation of the vehicle-battery system, the heat-transfer fluid is channeled through the heat-transfer tube section. The technology in various embodiments also includes a fluid modification device and a computerized controller for controlling the fluid modification device or other operations of the system such as pumping of the heat-transfer fluid.

Abstract: A method and a test fixture for evaluating a battery cell are described, wherein the battery cell is composed of a cell body having a plurality of electrode foils that are joined to both a positive terminal and a negative terminal at weld junctions. The method includes retaining the cell body of the battery cell in a first clamping device and gripping one of the positive and negative terminals in a terminal gripper. A dynamic stress end effector coupled to the terminal gripper is employed to apply a vibrational excitation load to the one of the positive and negative terminals. Impedance between the positive terminal and the negative terminal is monitored via a controller, and integrity of the weld junction of the one of the positive and negative terminals is evaluated based upon the impedance.

Abstract: A method and a test fixture for evaluating a battery cell composed of a cell body having a plurality of electrode foils, a positive terminal and a negative terminal, wherein the positive terminal and the negative terminal are each joined to the cell body at weld junctions. This includes retaining the cell body of the battery cell in a first clamping device. The terminal is grasped in a terminal gripper. A dynamic stress end effector coupled to the terminal gripper applies a vibrational excitation load to the terminal. A static stress end effector applies a static load to the terminal. Integrity of the weld junction is evaluated based upon the applied static load.

Abstract: A method and an apparatus for evaluating a battery cell. The battery cell may include a hermetically sealed outer casing, a plurality of electrically conductive components enclosed within the outer casing, an electrically conductive terminal having a proximal end that extends within the outer casing and a distal end that extends in a longitudinal direction relative to the battery cell outside the outer casing, and a solid electrical and mechanical joint formed between one or more of the electrically conductive components and the proximal end of the electrically conductive terminal. Evaluation of the battery cell may include measuring the impedance of the battery cell while applying a longitudinal pulling force or a transverse bending force to the electrically conductive terminal and the solid electrical and mechanical joint.

Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

Abstract: A method and a test fixture for evaluating a battery cell are described, wherein the battery cell is composed of a cell body having a plurality of electrode foils that are joined to both a positive terminal and a negative terminal at weld junctions. The method includes retaining the cell body of the battery cell in a first clamping device and gripping one of the positive and negative terminals in a terminal gripper. A dynamic stress end effector coupled to the terminal gripper is employed to apply a vibrational excitation load to the one of the positive and negative terminals. Impedance between the positive terminal and the negative terminal is monitored via a controller, and integrity of the weld junction of the one of the positive and negative terminals is evaluated based upon the impedance.

Abstract: A mechanically conformable micro-heat exchanger for use in managing temperature of a subject component. The exchanger includes a flexible fluid tube. In various embodiments, the tube is connected to a flexible substrate, such as by a flexible polymer. The exchanger can be changed manually from an initial shape to a first shape to conform to a shape of the subject component. The flexible fluid tube is configured to channel heat-transfer fluid through a heat-transfer tube section of the tube. The heat-transfer fluid is configured to cool or heat the subject component when, in operation of the mechanically conformable micro-heat exchanger, the heat-transfer fluid is channeled through the heat-transfer tube section.