A method and system for detecting a welded nickel sheet of an isolation plate

Abstract

The application discloses a kind of isolation plate welding nickel sheet detection method, establishes detection model, light source control set, displacement point set;Defect sample detection sampling, carry out the switching position adjustment of point set in turn, carry out the full sampling of light source control set on each point set point;Detection analysis determines at least one point position matched with each detection item of defect sample and the light source control matched with corresponding point position, and updates detection model;According to the detection operation of updated detection model is carried out.The application method only needs a detection station, through its point position and light source control cooperation, it can meet the detection demand of nickel sheet welding defect on isolation plate, and can realize the automatic update of detection model, without carrying out detection station hardware adjustment.Satisfy material relative angle compensation and light source reference intensity compensation demand, realize the dynamic compensation when executing detection model, ensure that detection is reliable and effective.

Description

Technical Field

[0001] This invention relates to a method and system for detecting nickel sheets welded to separator plates, belonging to the technical field of power battery testing. Background Technology

[0002] The power battery system (power battery PACK, battery pack) is the core energy source that provides driving power for new energy vehicles and is one of the most critical components of new energy vehicles. The power battery system mainly consists of battery modules, electrical systems, thermal management systems, housings, and BMS, etc. The housing encapsulates the battery modules, electrical systems, thermal management systems, and BMS, forming the main body of the power battery system.

[0003] To ensure the safety of the battery box, it is necessary to collect the temperature and voltage of the battery cells. Therefore, an isolation plate is used to connect the corresponding wiring harnesses to meet the communication data collection requirements. Generally, the isolation plate has a conductive alignment area distributed according to the position of the battery cells. The conductive alignment area includes a plate and a nickel plate welded to the plate. The nickel plate has notches for wiring harness mating, and wiring harness conduction mating is performed during assembly.

[0004] The separator is a core safety component, which is crucial to the overall safety and stability of the battery box. The conductivity reliability of the nickel strips and the battery contacts on it is very high. Therefore, after the nickel strips are welded, an appearance inspection is required to ensure the welding quality and relative position accuracy of the nickel strips and the battery contacts.

[0005] When performing specific inspection operations, the inspection items generally include: weld size, offset position of nickel sheet relative to the plate, blue area of ​​nickel sheet poor soldering, nickel sheet over-soldering, etc. The traditional inspection method is to use a fixed fixture to mount the isolation plate and then use line laser scanning. This method is slow, costly and has low production line operating efficiency.

[0006] To address this issue, existing technologies typically employ linear conveyor belts to transport the isolation plates, with several detection positions set along the transport path. Detection is performed after adjusting and fixing the light source for specific defects at each detection position. This requires at least three detection positions to meet the image acquisition and defect detection needs of high-speed operating isolation plates. However, the detection items on the isolation plates are open-ended, allowing for the addition or removal of detection items. Therefore, when changing product models or adjusting product detection items, manual rearrangement of the detection positions and adjustment of the light source are required, which is very labor-intensive and time-consuming. Furthermore, the detection accuracy of the detection positions is subject to certain errors, which can easily affect the accuracy of the detection results. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of the prior art and to propose a method and system for detecting nickel sheets welded to isolation plates, which are difficult to set up detection positions and light source sections in traditional methods for operating isolation plates.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for inspecting nickel sheets welded to isolation plates is applied to an inspection system. The inspection system includes a linear conveyor line for linearly conveying isolation plates, and an inspection station set on the linear conveyor line. The inspection station includes a hemispherical light source cover with an open, vertically facing the linear conveyor line, an image acquisition unit disposed at the top of the hemispherical light source cover and vertically facing the linear conveyor line, and a controller communicatively connected to the light source cover and the image acquisition unit. The light source cover includes several circumferential light source rings disposed at intervals within the hemispherical light source cover, each circumferential light source ring being composed of several interconnected light source units. The image acquisition unit has an image center located on the linear conveyor line, with each light source unit facing the image center. The hemispherical light source cover has a linearly adjustable displacement relative to the linear conveyor line. The method includes: S1. Establish a detection model for isolation plates that allows for the addition or removal of detection items; S2. Based on the illumination intensity of individual light sources and the on / off combinations of any individual light sources, a set of supplementary light source controls is formed, consisting of several supplementary light source controls. S3. Obtain the set of displacement alignment points of the isolation plate according to the conveying speed of the linear conveying production line and the acquisition frequency of the image acquisition unit; S4. Use defect samples that cover all defects to perform detection sampling. Place the defect samples on the detection station of the linear conveyor production line. Adjust the corresponding displacement of the hemispherical supplementary light cover by sequentially switching the position of the alignment point set. Perform full sampling of the supplementary light source control set at each point of the alignment point set. S5. Perform detection analysis on all samples of each pair of points in the set of points, determine at least one point that matches each detection item of the defective sample and the supplementary light source control that matches the corresponding point, and update the detection items in the detection model by matching points and supplementary light source control to obtain the updated detection model. S6. Based on the updated detection model, the detection operation is carried out. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously conveys the isolation plate to be tested. The image acquisition unit acquires images according to the acquisition frequency. After the first acquired image is obtained, the location of each detection item is determined by continuous shooting.

[0009] Preferably, in step S2, any of the supplementary light source controls in the supplementary light source control set has circumferential angle adjustment for circumferential switching of illumination angle.

[0010] Preferably, in step S6, when the image acquisition unit first obtains the acquired image, it obtains the skew angle information between the current isolation plate and the conveying direction of the linear conveyor line, and performs circumferential skew angle adjustment compensation for the supplementary light source control based on the skew angle information.

[0011] Preferably, the isolation plate is provided with several nickel sheet welding parts. In step S1, the detection model includes a detection sub-model for any of the nickel sheet welded parts; In step S5, at least three points are determined that match each detection item corresponding to each nickel sheet weld in the defective sample, and supplementary light source control is provided to coordinate with the corresponding points. In step S6, a detection sample database is constructed. When an image acquisition and judgment failure occurs in any detection item of the nickel sheet welding part, supplementary light source control and adjustment are performed through the corresponding detection item of the effective detection sub-model. An alarm is triggered when all detection items for any nickel sheet welded part fail.

[0012] Preferably, in step S2, any of the supplementary light source controls in the supplementary light source control set has supplementary light source reference intensity compensation adjustment; In step S4, the reference illumination for the detection station is determined and several on-site light sources are adjusted. In step S5, the adjustment of the reference illumination and several field light sources is performed to obtain the coefficients of the supplementary light source reference intensity compensation adjustment of the supplementary light source reference control set for the reference illumination and the supplementary light source reference intensity compensation adjustment of the supplementary light control set after adjustment relative to the field light sources. In step S6, the reference intensity of the supplementary light source in the supplementary light control set is adjusted according to the on-site light source of the detection station.

[0013] This invention also proposes a detection system for a method of detecting nickel sheets welded to isolation plates, wherein the controller includes: The detection model unit is used to establish a detection model for the isolation plate with the ability to add or remove detection items; The supplementary light source control set unit is used to form a supplementary light source control set consisting of several supplementary light source controls based on the illumination intensity of individual light sources and the on / off combination of any individual light sources. The image acquisition matching unit is used to obtain the set of displacement alignment points of the isolation plate according to the conveying speed of the linear conveyor line and the acquisition frequency of the image acquisition unit; The pre-inspection sampling unit uses defect samples covering all inspection items for inspection sampling. The defect samples are placed on the inspection station of the linear conveyor production line. The corresponding displacement of the hemispherical supplementary light cover is adjusted by sequentially switching the position of the alignment point set. At each alignment point set, all sampling of the supplementary light source control set is performed. The analysis and update detection unit is used to perform detection analysis on all samples of each pair of points in the set of points, determine at least one point that matches each detection item of the defective sample and the supplementary light source control that matches the corresponding point, and update the detection items in the detection model by matching points and supplementary light source control to obtain the updated detection model. The detection execution unit is used to perform detection operations based on the updated detection model. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously transports the isolation plate to be detected. The image acquisition unit acquires images according to the acquisition frequency and determines the location of each detection item by continuously shooting after the first acquired image.

[0014] Preferably, the supplementary light source control assembly unit includes a circumferential angle adjustment control module for adjusting the circumferential switching illumination angle of any of the supplementary light sources controlled in the supplementary light source control assembly.

[0015] Preferably, the detection execution unit includes a circumferential skew angle adjustment and compensation module, which obtains the skew angle information between the current isolation plate and the conveying direction of the linear conveyor line when the image acquisition unit first obtains the acquired image, and performs circumferential skew angle adjustment and compensation for supplementary light source control based on the skew angle information.

[0016] Preferably, the isolation plate is provided with several nickel sheet welding parts. The detection model unit includes a detection sub-model module for storing detection sub-models for any of the nickel sheet welds within the detection model; The analysis and update detection unit includes a supplementary light source control module, used to determine at least three points that match each detection item corresponding to each nickel sheet weld in the defective sample, and to control the supplementary light source in coordination with the corresponding points. The detection execution unit includes a detection sample judgment module, which is used to construct a detection sample database. When the image acquisition judgment fails for any detection item of any nickel sheet welded part, the corresponding detection item of the effective detection sub-model is used to adjust the supplementary light source. When all detection items of any nickel sheet welded part fail, an alarm is triggered.

[0017] Preferably, the supplementary light source control assembly unit includes a reference intensity compensation module, which is used for reference intensity compensation adjustment of any supplementary light source controlled by any of the supplementary light sources in the supplementary light source control assembly; The pre-detection sampling unit includes an on-site light source intensity module, which is used to determine the reference illumination of the detection station and adjust several on-site light sources. The analysis and update detection unit includes a compensation calculation module, which is used to adjust the reference illumination and several field light sources to obtain the coefficients of the supplementary light source reference intensity compensation adjustment for the supplementary light control set for the reference illumination and the supplementary light control set after adjustment relative to the field light sources. The detection execution unit includes a supplementary light source reference illumination compensation module, which is used to adjust the supplementary light source reference intensity compensation of the supplementary light control set according to the on-site light source of the detection station.

[0018] The beneficial effects of this invention are mainly reflected in: 1. Only one inspection station is needed. By coordinating its location with the supplementary light source control, the inspection requirements for nickel sheet welding defects on the isolation plate can be met. The inspection model can be automatically updated without the need for hardware adjustment of the inspection station.

[0019] 2. Meets the requirements for material relative deviation angle compensation and supplementary light source reference intensity compensation, realizes dynamic compensation during the execution of the detection model, and ensures reliable and effective detection.

[0020] 3. The supplementary light source control is very comprehensive. When collecting and analyzing data on defective samples, it can obtain very accurate and suitable points and supplementary light source control, which reduces the difficulty of back-end processing and calculation and improves the detection efficiency. It is especially suitable for ultra-high-speed detection production lines. Attached Figure Description

[0021] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a flowchart illustrating a method for detecting nickel sheets welded to a separator plate according to the present invention.

[0022] Figure 2 This is a schematic flowchart of a preferred embodiment of the method for detecting nickel sheets welded to a separator plate according to the present invention.

[0023] Figure 3 This is a schematic diagram of the detection system of the detection method for detecting nickel sheets welded to isolation plates according to the present invention.

[0024] Figure 4 This is a schematic diagram of the controller in the detection system of the present invention.

[0025] Figure 5 This is a schematic diagram of the supplementary light source control set and the alignment point set in the nickel sheet welding detection method of the isolation plate of the present invention.

[0026] Figure 6 This is a photograph of the isolation plate captured by the image acquisition unit in this invention.

[0027] Figure 7 This is an NG (Not Good) judgment photograph of a nickel sheet welded part acquired by the image acquisition unit in this invention.

[0028] Figure 8 This is another NG (Not Good) judgment photograph of a nickel sheet welding section acquired by the image acquisition unit in this invention.

[0029] Figure 9 This is another NG (Not Good) judgment photograph of a nickel sheet welding part acquired by the image acquisition unit in this invention. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in the present application can be combined with each other.

[0032] This invention provides a method for detecting nickel sheets welded to isolation plates, which is applied to a detection system, such as... Figure 3 As shown, the detection system includes a linear conveyor line 200 for linear conveying of a partition plate 100, and a detection station 300 set on the linear conveyor line 200. The detection station 300 includes a hemispherical light cover 400 with a supplementary light source that is open and vertically facing the linear conveyor line, an image acquisition unit 500 set at the top of the hemispherical light cover 400 and vertically facing the linear conveyor line, and a controller 600 that is communicatively connected to the supplementary light source and the image acquisition unit. The supplementary light source includes a plurality of circumferential light source rings 700 arranged at intervals within the hemispherical light cover. Each circumferential light source ring is composed of a plurality of interconnected light source units 800. The image acquisition unit has an image center located on the linear conveyor line, with each light source unit facing the image center. The hemispherical light cover has a linearly adjustable displacement relative to the linear conveyor line.

[0033] This inspection system has a wide range of applications and is a common system for inspecting the outer surfaces of electronic components and products. Products are transported via a linear conveyor line 200 and then inspected at the inspection station 300 for defects. Supplemental lighting is typically provided using ring-shaped or dome-shaped light sources. Images are acquired by an image acquisition unit and then communicated and analyzed by a controller to meet the defect detection requirements.

[0034] During the inspection of the isolation plate, the welding quality requirements for the nickel sheets and aluminum foil are relatively high. The traditional single inspection station 300 is difficult to meet the inspection requirements and accuracy of the defects. Multiple inspection stations 300 need to be set up on the linear conveyor line 200 for corresponding inspections. The inspection items include at least the weld size, the offset position of the nickel sheet relative to the foil, the blue area of ​​the nickel sheet with poor welding, and the nickel sheet over-welding. Therefore, when adjusting each inspection station, it is necessary to adjust the lighting angle, image acquisition angle, etc., which is very difficult. In particular, there are several welded nickel sheets with a matrix distribution on the isolation plate, making it difficult to efficiently, accurately and comprehensively judge the inspection items through a single inspection station. In addition, there are many types of isolation plates and many variations in the inspection items of the nickel sheets, making it difficult to readjust the inspection stations after they have been fixed.

[0035] To address this issue, the present invention proposes a method for detecting nickel sheets welded to isolation plates, such as... Figure 1 The following is a flowchart of the detection process. First, a testing model for the isolation plate with the ability to add or remove testing items is established. The testing model contains several testing items for defects in the welding quality of nickel sheets, and these testing items can be added or removed according to the defect requirements of the product to be tested.

[0036] For the hemispherical fill light cover 400, a fill light control set consisting of several fill light control units is formed based on the illumination intensity of individual light sources and the on / off combination of any individual light source. The fill light control set is obtained by arranging and combining the number of individual light sources and the number of brightness adjustment gradients of individual light sources.

[0037] Next, the acquisition frequency of the linear conveyor line and the image acquisition unit is matched, and the set of displacement alignment points of the isolation plate is obtained according to the conveying speed of the linear conveyor line and the acquisition frequency of the image acquisition unit.

[0038] The acquisition frequency is the gap rate of image acquisition by the image acquisition unit. Generally, the supplementary light source has an exposure time, that is, the continuous acquisition interval is greater than the current exposure time. The linear material conveying distance of each image acquisition is obtained by the conveying speed of the linear conveyor production line. Generally, there is an effective stroke during the operation of the isolation plate, and there are dozens or even hundreds of points in this effective stroke.

[0039] Defect samples covering all inspection items are used for inspection sampling. The defect samples are placed on the inspection station of the linear conveyor production line. The corresponding displacement of the hemispherical supplementary light cover is adjusted by sequentially switching the position of the alignment point set. At each point of the alignment point set, the entire supplementary light source control set is sampled.

[0040] The displacement of the hemispherical fill light cover covers the effective stroke of its relative linear conveyor line. By moving the corresponding detection station points in the positive and negative directions, the full point switching of the displacement alignment point set is realized. At each point, the entire image is acquired by controlling the set of fill light sources, thus obtaining images of several points controlled by several fill light sources.

[0041] Then, for all the sampling points in each pair of points, the detection analysis of each detection item is performed to determine at least one point that matches each detection item of the defective sample and the supplementary light source control that matches the corresponding point. The detection items in the detection model are then updated by matching points and supplementary light source control to obtain an updated detection model.

[0042] That is, the defective sample contains accurate data on all the defects in the test items. The defect-specific data is processed and information is captured on the images controlled by several supplementary light sources at several points. This processing and information capture is a prior art. The captured defect-specific data is compared with the accurate data of the defective sample. The image that is closest to the accurate data within its error range is taken as the target image. The location of the target image and the corresponding supplementary light source control are used as the detection control parameters for the test item.

[0043] To elaborate on this step, under normal circumstances, the image acquisition unit 500 will acquire hundreds of images during the full-point switching process. With a fixed traditional light source, the backend needs to analyze hundreds of images for image processing, edge definition, and defect analysis and identification, which involves a huge amount of computation. In this method, it is only necessary to consider the images generated by the points corresponding to the detection items under the control of a specific supplementary light source, which can meet the requirements for accurate defect detection and significantly improve the detection rate.

[0044] The testing operation is carried out according to the updated testing model. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously transports the isolation plate to be tested. The image acquisition unit acquires images according to the acquisition frequency, and determines the location of each test item by continuously shooting after the first acquired image.

[0045] Specifically, under normal circumstances, the image acquisition unit will continuously acquire images. When the image of the current isolation plate is acquired for the first time, it will trigger the initial point alignment. Then, with the current point as a reference, the point rate matching and control of each subsequent detection item will be performed, thus meeting the requirements for point and control adaptation.

[0046] This detection method eliminates the need for hardware adjustment at the detection station, meets the requirements for generating and updating automated detection models to adapt to defective products, and satisfies the need for efficient adaptation of isolation boards of various specifications and with different detection defects, thus greatly improving detection operation efficiency and debugging efficiency.

[0047] like Figure 2As shown, any of the supplementary light source controls in the supplementary light source control assembly has circumferential angle adjustment for switching the illumination angle. When the image acquisition unit first obtains the acquired image, it obtains the angle information between the current isolation plate and the conveying direction of the linear conveyor line, and performs circumferential angle adjustment compensation for the supplementary light source control based on the angle information.

[0048] Specifically, when the isolation plate is fed through the linear conveyor line 200, it has a deflection angle that is linearly opposite to the linear conveyor line 200. The nickel sheet welding parts are densely distributed on the isolation plate. Even a slight offset will cause a change in the illumination angle of the light source at a specific point, affecting the image acquisition and judgment of the detection items.

[0049] In response to this situation, when the image acquisition unit first obtains the acquired image, it calculates the angle between the edge of the image and the conveying direction of the linear conveyor line, and performs circumferential angle adjustment and compensation.

[0050] To explain in detail, such as Figure 5 As shown, its several circumferential light source rings 700 have radially matched individual light source units 800. Generally, the central angle corresponding to a single light source unit is the minimum adjustable deflection angle, such as... Figure 5 As shown, the light source unit 800 is not further divided into individual units. Each circumferential light source ring 700 consists of 120 light source units 800. The minimum adjustable deflection angle in the direction of the arrow is 3°, thus enabling fine-grained deflection angle adjustment. While this 120 light source units 800 represent the best currently achievable solution, its cost is relatively high. Generally, a minimum adjustable deflection angle of 15° is sufficient to meet requirements. ±10° is sufficient for adjusting the relative deflection of the feeding direction.

[0051] In one specific embodiment, the isolation plate is provided with several nickel sheet welding parts, such as Figure 1 and Figure 2 As shown, the detection model includes a detection sub-model for any nickel sheet weld.

[0052] Identify at least three points that match each inspection item corresponding to each nickel sheet weld in the defective sample, and control the supplementary light source to match the corresponding points.

[0053] A database of test samples is constructed. When the image acquisition and judgment of any test item in any nickel sheet welded part fails, the corresponding test item of the effective test sub-model is used to adjust the supplementary light source. When all test items of any nickel sheet welded part fail, an alarm is triggered.

[0054] Specifically, since there are several nickel sheet welding parts on the isolation plate, there are multiple targeted detection sub-models in the detection model, which makes the control of the point and supplementary light source richer and more adaptable.

[0055] Because the nickel sheet welding area is relatively small and has a large number of welded parts, it is easy to fail when adapting a single point. To address this, at least three points and corresponding supplementary light source control are used for adaptation. In this way, only one of the three points needs to have valid information to meet the detection and judgment requirements.

[0056] like Figure 6 As shown, this is an image captured at one point on the isolation plate. It can be seen that the area of ​​the nickel sheet in the overall image is relatively small. There are 10 nickel sheet welds in the overall image, and these 10 welds exhibit image differences. Therefore, a detection sub-model was used to perform supplementary lighting and point matching for the detection of individual nickel sheet welds, thereby meeting the requirements for accurate detection. Figures 7 to 9 The image shown is of a single nickel sheet welded part. It is an image of identification information after image processing. By combining and judging at least three points, it can meet the requirements of accurate detection.

[0057] Of course, since the points are prone to judgment failure, such as when the coordinates, area, or over-welding identification cannot be obtained due to local ambiguity, the control of the supplementary light source is adjusted through the associated points, and the judgment failure is corrected in the next inspection. When the correction can be achieved, the inspection model is updated. When all the inspection items of any nickel sheet welded part fail, an alarm is triggered. At this time, manual intervention is required to re-collect defect sample data and readjust the inspection station.

[0058] In one specific embodiment, such as Figure 2 As shown, any supplementary light source control in the supplementary light source control set has supplementary light source reference intensity compensation adjustment; the reference illumination of the detection station is determined and several field light sources are adjusted; the adjustment of the reference illumination and several field light sources is performed to obtain the coefficient of supplementary light source reference intensity compensation adjustment of the supplementary light control set for the reference illumination and the supplementary light control set after adjustment relative to the field light sources; the supplementary light source reference intensity compensation adjustment of the supplementary light control set is performed according to the field light sources of the detection station.

[0059] Specifically, the ambient light source in the detection system varies significantly. Therefore, an active adjustment of the on-site light source is used to obtain the coefficient for compensating the reference intensity of the supplementary light source. This coefficient is mainly obtained by constructing a corresponding detection model using on-site light sources of different intensities during defect sample sampling data acquisition, and then adjusting the reference intensity of the supplementary light source and the intensity of the compensating supplementary light to obtain a comparison coefficient before and after. For example, the brightness of the on-site light source is generally below 100 lumens, while the brightness of a single supplementary light source exceeds 700 lumens. Therefore, a matching coefficient is applied to match the changes in the on-site light source. This coefficient is based on simple mathematical calculations and will not be elaborated here. It only needs to meet the requirement of automatic adjustment to adapt the illumination intensity of the single light source to the on-site light source.

[0060] It should be noted that a lightweight network architecture is adopted when building the detection model. The updated detection model obtained by corresponding defective sample standard is used as the basis. During continuous detection operation, the results of the detection sample database are screened and trained based on the basic detection model to obtain the fixed model elements for the detection model. When changing products, the fixed model elements can be used to achieve rapid adaptation without defective samples. This makes the product change more efficient, the debugging more sequential, the calculation faster, and the recognition accuracy guaranteed.

[0061] To implement the method described in this case, the following are proposed: Figure 3 The system shown is a detection method for detecting nickel sheets welded to isolation plates. Figure 4 As shown, the controller package: The detection model unit is used to build a detection model for the isolation plate with the ability to add or remove detection items. In other words, it can realize the construction and editing of the detection model, and realize the generation and control of the corresponding detection model execution instructions.

[0062] The supplementary light source control set unit is used to form a supplementary light source control set consisting of several supplementary light source controls based on the illumination intensity of individual light source units and the on / off combination of any individual light source units, so as to meet the execution requirements of each supplementary light source control.

[0063] The image acquisition matching unit is used to obtain the set of displacement alignment points of the isolation plate according to the conveying speed of the linear conveyor line and the acquisition frequency of the image acquisition unit.

[0064] The pre-inspection sampling unit uses defect samples covering all inspection items for inspection sampling. The defect samples are placed on the inspection station of the linear conveyor production line. By adjusting the corresponding displacement of the hemispherical supplementary light cover, the position of the alignment point set is switched sequentially. At each position of the alignment point set, all sampling of the supplementary light source control set is performed.

[0065] The analysis and update detection unit is used to perform detection analysis on all samples of each pair of points in the set of points, determine at least one point that matches each detection item of the defective sample and the supplementary light source control that matches the corresponding point, and update the detection items in the detection model by matching points and supplementary light source control to obtain the updated detection model.

[0066] The detection execution unit is used to perform detection operations based on the updated detection model. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously transports the isolation plate to be detected. The image acquisition unit acquires images according to the acquisition frequency and determines the location of each detection item by continuously shooting after the first acquired image.

[0067] In one specific embodiment, the supplementary light source control assembly unit includes a circumferential angle adjustment control module for adjusting the circumferential switching illumination angle of any of the supplementary light sources controlled in the supplementary light source control assembly.

[0068] In one specific embodiment, the detection execution unit includes a circumferential skew angle adjustment and compensation module, which obtains the skew angle information between the current isolation plate and the conveying direction of the linear conveyor line when the image acquisition unit first obtains the acquired image, and performs circumferential skew angle adjustment and compensation for supplementary light source control based on the skew angle information.

[0069] In one specific embodiment, the isolation plate is provided with a plurality of nickel sheet welded parts, and the detection model unit includes a detection sub-model module for storing the detection sub-model for any nickel sheet welded part within the detection model; the analysis and update detection unit includes a supplementary light source control module for determining at least three points that match each detection item corresponding to each nickel sheet welded part in the defective sample and the supplementary light source control that cooperates with the corresponding points.

[0070] The detection execution unit includes a detection sample judgment module, which is used to build a detection sample database. When the image acquisition judgment fails in any detection item of any nickel sheet welded part, the corresponding detection item of the effective detection sub-model is used to adjust the supplementary light source. When all detection items of any nickel sheet welded part fail, an alarm is triggered.

[0071] In one specific embodiment, the supplementary light source control set unit includes a reference intensity compensation module, which is used for adjusting the reference intensity compensation of any supplementary light source controlled in the supplementary light source control set.

[0072] The pre-detection sampling unit includes a field light source intensity module, which is used to determine the reference illumination of the detection station and adjust several field light sources.

[0073] The analysis and update detection unit includes a compensation calculation module, which is used to adjust the reference illumination and several field light sources to obtain the coefficients of the supplementary light source reference intensity compensation adjustment for the supplementary light control set for the reference illumination and the supplementary light control set after adjustment relative to the field light sources.

[0074] The detection execution unit includes a supplementary light source reference illumination compensation module, which is used to adjust the supplementary light source reference intensity compensation of the supplementary light control set according to the on-site light source of the detection station.

[0075] The controller, composed of various units and modules, can meet the requirements of model storage, control command generation, corresponding model updating, and control command compensation for the detection method of nickel sheet welding on isolation plates.

[0076] As described above, only one inspection station is needed. By coordinating its location with the supplementary light source control, the inspection requirements for nickel sheet welding defects on the isolation plate can be met. Furthermore, the inspection model can be automatically updated without requiring hardware adjustments to the inspection station. It satisfies the requirements for material relative angle compensation and supplementary light source reference intensity compensation, enabling dynamic compensation during inspection model execution and ensuring reliable and effective inspection. The supplementary light source control is highly sophisticated. During data acquisition and inspection analysis of defective samples, very precise and suitable location and supplementary light source control are obtained, reducing the computational complexity of back-end processing and improving inspection efficiency, making it particularly suitable for ultra-high-speed inspection production lines.

[0077] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0078] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A method for inspecting nickel sheets welded to a separator plate, applied to an inspection system, the inspection system comprising a linear conveyor line for linearly conveying separator plates, an inspection station set on the linear conveyor line, the inspection station comprising a hemispherical light source with an open top perpendicular to the linear conveyor line, an image acquisition unit disposed at the top of the hemispherical light source and perpendicular to the linear conveyor line, and a controller communicatively connected to the light source and the image acquisition unit, the light source comprising a plurality of circumferential light source rings disposed at intervals within the hemispherical light source cover, each circumferential light source ring being composed of a plurality of interconnected light source units, the image acquisition unit having an image center located on the linear conveyor line, each light source unit facing the image center, and the hemispherical light source cover having a linearly adjustable displacement relative to the linear conveyor line, characterized in that... The method includes: S1. Establish a detection model for isolation plates that allows for the addition or removal of detection items; S2. Based on the illumination intensity of individual light sources and the on / off combinations of any individual light sources, a set of supplementary light source controls is formed, consisting of several supplementary light source controls. S3. Obtain the set of displacement alignment points of the isolation plate according to the conveying speed of the linear conveying production line and the acquisition frequency of the image acquisition unit; S4. Use defect samples that cover all defects in the detection items for detection sampling. Place the defect samples on the detection station of the linear conveyor production line. By displacing the hemispherical supplementary light cover accordingly, the entire set of displacement alignment points is switched sequentially. At each point of the displacement alignment point set, the entire set of supplementary light source control is sampled. S5. Perform detection analysis on all sampling points of each displacement alignment point set, determine at least one point that matches each detection item of the defect sample and the supplementary light source control that matches the corresponding point, and update the detection items in the detection model by matching points and supplementary light source control to obtain an updated detection model. S6. The detection operation is carried out according to the updated detection model. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously conveys the isolation plate to be tested. The image acquisition unit acquires images according to the acquisition frequency. After the first acquired image is obtained, the initial point alignment is triggered. Then, with the current point as a reference, the point of each detection item is determined by continuous shooting.

2. The method for detecting nickel sheets welded to a separator plate according to claim 1, characterized in that: In step S2, any of the supplementary light source controls in the supplementary light source control set has circumferential angle adjustment for circumferential switching of illumination angle.

3. The method for detecting nickel sheets welded to a separator plate according to claim 2, characterized in that: In step S6, when the image acquisition unit first obtains the acquired image, it obtains the deflection angle information between the current isolation plate and the conveying direction of the linear conveying production line, and performs circumferential deflection angle adjustment compensation for supplementary light source control based on the deflection angle information.

4. The method for detecting nickel sheets welded to a separator plate according to claim 1, characterized in that: The isolation plate is provided with several nickel sheet welding sections. In step S1, the detection model includes a detection sub-model for any of the nickel sheet welded parts; In step S5, at least three points are determined that match each detection item corresponding to each nickel sheet weld in the defective sample, and supplementary light source control is provided to coordinate with the corresponding points. In step S6, a detection sample database is constructed. When an image acquisition and judgment failure occurs in any detection item of the nickel sheet welding part, supplementary light source control and adjustment are performed through the corresponding detection item of the detection sub-model. An alarm is triggered when all detection items for any nickel sheet welded part fail.

5. The method for detecting nickel sheets welded to a separator plate according to claim 1, characterized in that: In step S2, any of the supplementary light source controls in the supplementary light source control set has supplementary light source reference intensity compensation adjustment; In step S4, the reference illumination for the detection station is determined and several on-site light sources are adjusted. In step S5, the reference illumination and several field light sources are adjusted to obtain a set of supplementary light source control for the reference illumination and a set of supplementary light source control after adjustment relative to the field light sources, and to obtain the coefficient of supplementary light source reference intensity compensation adjustment. In step S6, the reference intensity compensation adjustment of the supplementary light source control set is performed based on the on-site light source at the detection station.

6. A detection system based on the detection method for nickel sheet welding of a separator plate according to any one of claims 1 to 5, characterized in that... : The controller includes: The detection model unit is used to establish a detection model for the isolation plate with the ability to add or remove detection items; The supplementary light source control set unit is used to form a supplementary light source control set consisting of several supplementary light source controls based on the illumination intensity of individual light sources and the on / off combination of any individual light sources. The image acquisition matching unit is used to obtain the set of displacement alignment points of the isolation plate according to the conveying speed of the linear conveyor line and the acquisition frequency of the image acquisition unit; The pre-detection sampling unit uses defect samples covering all detection items for detection sampling. The defect samples are placed on the detection station of the linear conveyor production line. By correspondingly displacing the hemispherical supplementary light cover, the entire set of displacement alignment points is switched sequentially. At each point of the displacement alignment point set, the entire set of supplementary light source control is sampled. The analysis and update detection unit is used to perform detection analysis on all samples of each displacement alignment point set, determine at least one point that matches each detection item of the defect sample and the supplementary light source control that matches the corresponding point, and update the detection items in the detection model by matching points and supplementary light source control to obtain the updated detection model. The detection execution unit is used to perform detection operations based on the updated detection model. The hemispherical fill light cover is reset and fixed. The linear conveyor line continuously transports the isolation plate to be detected. The image acquisition unit acquires images according to the acquisition frequency. After the first acquired image is obtained, it triggers the initial point alignment. Then, with the current point as a reference, it determines the point of each detection item for continuous shooting.

7. The detection system for the method of detecting nickel sheets welded to a separator plate according to claim 6, characterized in that: The supplementary light source control assembly unit includes a circumferential angle adjustment control module, which is used to adjust the circumferential switching illumination angle of any of the supplementary light sources controlled in the supplementary light source control assembly.

8. The detection system for the method of detecting nickel sheets welded to a separator plate according to claim 7, characterized in that: The detection execution unit includes a circumferential skew angle adjustment and compensation module, which obtains the skew angle information between the current isolation plate and the conveying direction of the linear conveyor line when the image acquisition unit first obtains the acquired image, and performs circumferential skew angle adjustment and compensation for supplementary light source control based on the skew angle information.

9. The detection system for the method of detecting nickel sheets welded to a separator plate according to claim 6, characterized in that: The isolation plate is provided with several nickel sheet welding sections. The detection model unit includes a detection sub-model module for storing detection sub-models for any of the nickel sheet welds within the detection model; The analysis and update detection unit includes a supplementary light source control module, used to determine at least three points that match each detection item corresponding to each nickel sheet weld in the defective sample, and to control the supplementary light source in coordination with the corresponding points. The detection execution unit includes a detection sample judgment module, which is used to construct a detection sample database. When the image acquisition judgment fails in any detection item of the nickel sheet welding part, the corresponding detection item of the detection sub-model is used to adjust the supplementary light source. When all detection items of any nickel sheet welding part fail, an alarm is triggered.

10. The detection system for the method of detecting nickel sheets welded to a separator plate according to claim 6, characterized in that: The supplementary light source control assembly unit includes a reference intensity compensation module, which is used for adjusting the reference intensity compensation of any supplementary light source controlled by any of the supplementary light sources in the supplementary light source control assembly. The pre-detection sampling unit includes an on-site light source intensity module, which is used to determine the reference illumination of the detection station and adjust several on-site light sources. The analysis and update detection unit includes a compensation calculation module, which is used to adjust the reference illumination and several field light sources to obtain a set of supplementary light source control for the reference illumination and a set of supplementary light source control after adjustment relative to the field light sources, and obtain the coefficient of the supplementary light source reference intensity compensation adjustment. The detection execution unit includes a supplementary light source reference illumination compensation module, which is used to adjust the supplementary light source reference intensity of the supplementary light source control set according to the on-site light source of the detection station.

Images