Method and system for online quality monitoring and control of a vibration welding process

1. A method for monitoring and controlling a vibration welding system having a sonotrode and an anvil during a vibration welding process, the welding system being configured for forming a welded joint at welding interfaces of a work piece that is clamped between the sonotrode and the anvil, wherein forming the welded joint is accomplished using a high-frequency mechanical vibration, the method comprising:

embedding at least one thermocouple inside of the anvil;

collecting a set of sensory data during formation of the welded joint using a plurality of sensors positioned with respect to the welding interfaces, wherein the embedded at least one thermocouple is one of the plurality of sensors, including directly measuring a temperature at the welding interfaces using the embedded at least one thermocouple and measuring a dynamic resistance between the anvil and the sonotrode, an acoustic signal, and a displacement of a portion of the welding system;

forming a total weld signature using the sensory data, wherein the total weld signature is defined by a plurality of different welding parameters from the set of sensory data;

extracting a present feature set from the total weld signature as a combined grouping of a plurality of the welding parameters using a host machine;

comparing and correlating the present feature set, via the host machine in real time during the formation of the welded joint, with validated information contained in a library to recognize a pattern in the combined grouping of the present feature set; and

executing a control action when the pattern in the extracted present feature set insufficiently matches the information in the library.

2. The method of claim 1 , wherein executing at least one control action includes at least one of: changing a control parameter of the vibration welding system, activating an indicator device, and temporarily stopping the vibration welding process.

3. The method of claim 1 , wherein the anvil includes a wall defining at least one bore and wherein the thermocouple is positioned within the bore.

4. The method of claim 1 , wherein extracting a present feature set from the weld signature using a host machine includes using at least one of: a neural network, finite element analysis, statistical regression analysis, and principal component analysis.

5. The method of claim 1 , wherein collecting a set of sensory data during the formation of the welded joint includes collecting the set of sensory data while vibration welding a conductive electrode tab of a multi-cell battery to a conductive interconnecting member of the multi-cell battery.

6. The method of claim 1 , wherein the anvil is segmented, and wherein embedding at least one thermocouple inside of the anvil includes positioning the thermocouple between adjacent segments of the anvil.

7. A welding system configured for forming a welded joint at welding interfaces of a work piece using a high-frequency mechanical vibration during a vibration welding process, the welding system comprising:

a plurality of sensors positioned with respect to the welding interfaces, including a thermocouple that is embedded inside of the anvil, wherein the sensors are operable for collecting a set of sensory data;

a sonotrode configured to vibrate during the vibration welding process, wherein the set of sensory data includes a temperature measured directly at the welding interfaces using the embedded thermocouple, a dynamic resistance between the anvil and the sonotrode, an acoustic signal, and a displacement of a portion of the welding system; and

a host machine having access to a library of validated information;

wherein the host machine is configured to:

extract a present feature set from a total weld signature formed using the sensory data, wherein the present feature set is a combined grouping of a plurality of welding parameters from the sensory data;

compare and correlate the extracted present feature set in real time with validated information contained in the library to recognize a pattern in the combined grouping of the present feature set; and

execute a control action when the pattern in the extracted present feature set insufficiently matches the information in the library.

8. The welding system of claim 7 , wherein the host machine is adapted for executing the at least one control action by at least one of: changing a control parameter of the welding system, activating an indicator device, and temporarily stopping the vibration welding process.

9. The welding system of claim 7 , wherein the welding system includes an anvil having a wall which defines a bore immediately adjacent to the welding interfaces, and wherein the thermocouple is positioned within the bore.

10. The welding system of claim 7 , wherein the host machine is configured to extract the feature set using principal component analysis.

11. The welding system of claim 7 , further comprising a welding anvil having a plurality of segments, wherein at least one of the sensors is positioned between adjacent segments of the plurality of segments.