Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A method of ultrasonically bonding a plurality of prismatic battery cell tabs to a bus bar within a battery section. The method includes arranging numerous prismatic battery cells such that cell tabs that extend from their lateral edge are substantially aligned along a stacking dimension defined within the battery section, and positioning a free end of at least one of the plurality of cell tabs in contact with a surface of the bus bar. The method is completed by contacting a bonding tool to no more than one surface of the positioned cell tab free end and ultrasonically bonding the positioned cell tab free end to a bus bar with the bonding tool. The one-sided bonding tool has a bonding tip cooperative with an ultrasonic excitation source.

Abstract: A method of ultrasonically bonding a plurality of prismatic battery cell tabs to a bus bar within a battery section. The method includes arranging numerous prismatic battery cells such that cell tabs that extend from their lateral edge are substantially aligned along a stacking dimension defined within the battery section, and positioning a free end of at least one of the plurality of cell tabs in contact with a surface of the bus bar. The method is completed by contacting a bonding tool to no more than one surface of the positioned cell tab free end and ultrasonically bonding the positioned cell tab free end to a bus bar with the bonding tool. The one-sided bonding tool has a bonding tip cooperative with an ultrasonic excitation source.

Abstract: A method of forming a resistance spot welding manufacture includes sandwiching a third metal layer between first and second metal layers to form a workpiece. The second layer has a surface defining an embossed region. The first layer has a first thickness, the third layer has a third thickness, and the second layer has a second thickness that is less than the first and third thicknesses so that a ratio of the first thickness to the second thickness is greater than about 2:1. The method includes positioning the workpiece between a first and second electrode so that the workpiece is disposed in electrically-conductive relationship with the first and the second electrodes, and applying an electrical current through the first electrode to concurrently melt the first and third layers and the surface at the embossed region to join the first and second layers to the third layer and form the manufacture.

Abstract: A resistance spot welding manufacture includes a first metal layer having a first thickness, a second metal layer having a faying surface defining an embossed region, wherein the second metal layer has a second thickness that is less than the first thickness so that a ratio of the first thickness to the second thickness is greater than about 2:1, a third metal layer sandwiched between the first metal layer and the embossed region, wherein the third metal layer has a third thickness that is greater than the second thickness, and a weld joint penetrating each of the first metal layer, the third metal layer, and the faying surface at the embossed region to thereby join each of the first metal layer and the second metal layer to the third metal layer. A method of forming a resistance spot welding manufacture is also disclosed.

Abstract: A method of joining the ends of wire windings for a motor stator or the like includes preparing a surface at each end (e.g., by removing any enamel coating), deforming the surfaces to produce knurls, striations, and the like, and then ultrasonically bonding the two surfaces to produce the bond between windings, thereby providing a joint with improved strength.

Abstract: A resistance spot welding manufacture includes a first metal layer having a first thickness, a second metal layer having a faying surface defining an embossed region, wherein the second metal layer has a second thickness that is less than the first thickness so that a ratio of the first thickness to the second thickness is greater than about 2:1, a third metal layer sandwiched between the first metal layer and the embossed region, wherein the third metal layer has a third thickness that is greater than the second thickness, and a weld joint penetrating each of the first metal layer, the third metal layer, and the faying surface at the embossed region to thereby join each of the first metal layer and the second metal layer to the third metal layer. A method of forming a resistance spot welding manufacture is also disclosed.

Abstract: A method of joining the ends of wire windings for a motor stator or the like includes preparing a surface at each end (e.g., by removing any enamel coating), deforming the surfaces to produce knurls, striations, and the like, and then ultrasonically bonding the two surfaces to produce the bond between windings, thereby providing a joint with improved strength.