Intelligent testing device and method for storage battery

Abstract

The invention provides an intelligent testing device and method for a storage battery, belongs to the technical field of rail trains, and aims at solving the problems that in the prior art, the voltage of the storage battery is detected one by one by mainly adopting a manual handheld measuring instrument, the labor intensity is high, and safety accidents are likely to occur. Comprising a base and a placement frame located on one side of the base, a mechanical arm is arranged on the base, a visual camera and a detection device matched with an electrode of a battery are arranged at the end, away from the base, of the mechanical arm, the detection device is used for detecting voltage and current of the battery, and the placement frame is used for placing a battery pack; the system further comprises a control system and a storage system, the control system controls the mechanical arm to drive the detection device to detect the battery to be detected according to an image, shot by the visual camera, of the battery pack, and the storage system is used for storing detection data. According to the invention, manual handheld operation is replaced by the mechanical arm, so that the high-strength problem of bending and frequent movement in traditional manual detection is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of rail vehicles, and in particular relates to an intelligent battery testing device and method. Background Art

[0002] As a core component of the onboard auxiliary power supply system, subway train batteries are responsible for providing power to emergency lighting, door control systems, and communications equipment. Their performance is directly related to train safety and the protection of passengers' lives and property. To eliminate the battery's "memory effect" and restore capacity, battery packs (for example, a single pack contains 78 nickel-metal hydride batteries densely arranged in rows and columns) must be regularly subjected to deep charge and discharge tests, during which individual cell voltage parameters must be frequently monitored.

[0003] Existing testing devices generally use the structure of a manual handheld measuring instrument, with a single voltage detection probe and a manual operating handle as the core components. This design exposes significant flaws when dealing with densely arranged battery packs: First, low detection efficiency. Because the battery packs are closely arranged in rows and columns (such as a 6-row 13-column layout), a single probe can only contact the electrodes point by point. Operators must frequently bend and lean sideways to locate different electrodes. Testing a single battery pack requires nearly 100 repetitive mechanical movements, which is extremely labor-intensive and time-consuming (a single pack test takes more than 2 hours). Second, there are significant safety hazards. The rigid connection structure between the manual operating handle and the probe lacks effective safety protection. When the battery leaks or shorts due to overcharging, aging, or other reasons, the operator needs to hold the handheld device close to the battery pack, which can easily cause personal injury due to contact with corrosive liquids or high-voltage arcs.

[0004] As the density of subway operations continues to increase, the frequency and accuracy requirements for battery testing are increasing simultaneously (for example, the testing cycle is shortened from once a day to once an hour). The existing rigid structure of "single probe + manual handle" can no longer meet the needs of efficient and safe maintenance. Especially for battery packs arranged in dense rows and columns, the low degree of automation of manual inspection leads to poor data consistency and a high missed detection rate (missed detection rate of 5%-10%), and it cannot adapt to high-frequency operation scenarios in the narrow space of subway maintenance rooms. Therefore, there is an urgent need for a battery testing device that can achieve automatic positioning, efficient detection and safety protection to solve the core pain points of manual operation in existing technologies. Summary of the Invention

[0005] In view of this, the present invention provides a battery testing device to solve the problem in the prior art that the battery voltage is mainly detected one by one by manually holding a measuring instrument, which is labor-intensive and prone to safety accidents.

[0006] The technical solution adopted in the present invention is as follows:

[0007] A battery intelligent testing device includes a base and a placement rack located on one side of the base. The base is provided with a robotic arm. An end of the robotic arm away from the base is provided with a visual camera and a detection device that cooperates with the battery electrodes. The detection device is used to detect the voltage and current of the battery. The placement rack is used to place a battery pack.

[0008] It also includes a control system and a storage system. The control system controls the robotic arm to drive the detection device to detect the battery to be detected based on the image of the battery pack taken by the visual camera, and the storage system is used to store the detection data.

[0009] It's important to note that this intelligent battery testing device utilizes a modular design consisting of "base support - robotic arm positioning - vision guidance - automatic inspection" to achieve efficient and safe testing. The base, serving as the basic support platform, is constructed from high-strength steel and features non-slip pads or anchor bolt holes on the bottom. A flange for the robotic arm is located in the center, and cable storage slots, along with power and data communication ports, ensure stability and facilitate signal exchange. The mounting bracket, located on one side of the base, is a frame-like structure with universal casters with brakes for easy movement and positioning. The robotic arm utilizes a six-axis servo mechanism with a working radius of 1010mm and a repeatability of 0.01mm. It features 360° horizontal rotation, ±90° vertical pitch, and ±180° end-of-line fine-tuning. The end connects to the testing device via a quick-release flange. A visual camera is mounted on the end of the robotic arm, utilizing a 2D / 3D vision solution with a tilted lens that covers the battery pack. The control system, based on an Advantech industrial computer with a built-in motion control card and an external touchscreen, enables rapid and accurate calculation of electrode coordinates and generation of collision-free trajectories. The storage system uses a SQL Server database to store the detection data in real time. During operation, the visual camera first takes images for pre-processing and electrode positioning, and then the robotic arm moves to the target position according to the calculated coordinates. The detection device contacts the electrode to collect data and store and verify it. Finally, the robotic arm drives the detection device to move to the next electrode. In summary, in the present invention, efficient and safe automated detection is achieved through the modular design of "base support-robotic arm positioning-visual guidance-automatic detection". With high-precision positioning and multi-dimensional flexible movement, combined with the intelligent recognition of the visual camera, the robotic arm can quickly calculate the electrode coordinates of densely arranged batteries, replacing the high-intensity operation of manual frequent bending and sideways movement.

[0010] Preferably, the end of the robotic arm is provided with a vertical plate, the vertical plate is provided with a mounting bracket, the mounting bracket is provided with a mounting hole, the mounting hole is vertically arranged, the detection device includes a probe, and the probe is detachably connected to the inner side of the mounting hole via a connecting device. The connecting device includes a tube body, the tube body passes through the mounting hole, the probe is mounted on the inner side of the rotating hole, and a first clamping plate and a second clamping plate are spaced apart on the side wall of the tube body, the first clamping plate is threadedly connected to the tube body, and the second clamping plate is fixedly connected to the tube body, and the first clamping plate and the second clamping plate are respectively located on either side of the mounting hole.

[0011] In this technical solution, it should be noted that the probe directly contacts the battery electrode to transmit detection signals such as voltage and current. The head is usually made of metal materials with excellent conductive properties (such as gold-plated copper alloy), and the surface is treated with anti-oxidation. The connecting device adopts a "tube body-double plywood" detachable structural design. The core components include a tube body, a first plywood and a second plywood: the tube body is a hollow cylindrical rod that passes through the mounting hole of the mounting frame in the vertical direction. Its inner wall provides an axial positioning channel for the probe to ensure that the axis of the probe is vertically aligned with the center of the battery electrode after insertion; the outer wall of the tube body is provided with a first plywood and a second plywood at intervals from top to bottom, wherein the inner wall of the first plywood is provided with a thread matching the outer wall of the tube body and can rotate and slide along the axial direction of the tube body, and the second plywood is fixed to the lower part (or upper part) of the tube body by interference fit or keyway. The outer diameters of both are larger than the diameter of the mounting hole and fit the upper and lower surfaces (or lower and upper surfaces) of the mounting frame respectively. During assembly, the tube body is inserted into the mounting hole from the bottom (or top) of the mounting frame. The second clamping plate pre-fixes and supports the lower surface (or upper surface) of the mounting frame. By rotating the first clamping plate clockwise, it moves upward (or downward) along the tube body thread and presses the upper surface (or lower surface) of the mounting frame. The axial clamping force generated by the thread transmission is used to rigidly fix the tube body and the mounting frame, thereby stably constraining the probe to the center position of the mounting hole. The core advantages of this structure are: through the thread adjustment function of the first clamping plate, it can adapt to different mounting frames with thicknesses of 10mm-30mm, avoiding customized processing; the double-clamping plate clamping design significantly improves the tube body's resistance to pull-out and torsional rigidity, preventing the probe from lateral displacement due to the force of the contact electrode during detection, ensuring stable contact resistance during voltage detection; during disassembly, only the first clamping plate needs to be rotated in the opposite direction to release the clamping force, and the tube body and probe can be quickly pulled out, realizing "replacement as soon as damage occurs". It is particularly suitable for the frequent probe wear scenarios in subway train battery testing. With the help of the automated operation of the robotic arm, the probe can be replaced within 30 seconds, greatly improving maintenance efficiency.

[0012] Preferably, the probe is connected to the inner side of the tube body via a bearing.

[0013] In this technical solution, it should be noted that the probe's structural design, in which the probe is connected to the inner side of the tube via a bearing, hinges on the inclusion of an axial support bearing within the tube, allowing the probe to slide flexibly relative to the tube while maintaining precise axial positioning. Specifically, a bearing mounting slot is provided in the middle or lower end of the tube's inner wall, housing a miniature bearing. The inner ring of the bearing is either interference-fitted or keyed to the outer wall of the probe's tail, while the outer ring fits snugly into the mounting slot, forming a sliding friction pair between the probe and the tube. This structure allows the probe to slide freely up and down along the tube's axis when contacting the battery electrodes, adapting to the height difference between the electrode surfaces. The bearing is typically made of corrosion-resistant stainless steel or engineering plastic (such as polytetrafluoroethylene), and its surface is lubricated to reduce friction. A dustproof seal is added to the outer side of the bearing to prevent the ingress of electrolyte mist or dust from the battery testing environment, which could affect its rotational flexibility. In this solution, the bearing's support enables the probe to achieve stress-free contact through self-adjustment during rapid positioning by a robotic arm, significantly reducing wear and tear between the probe and the electrode, thereby extending its service life.

[0014] Preferably, a connecting frame is provided on the vertical plate, and the visual camera is provided on the connecting frame.

[0015] Preferably, a support plate is provided on one side of the vertical plate, and an infrared temperature probe electrically connected to the control system is provided on the support plate. When the infrared temperature probe detects that the battery temperature exceeds a threshold, the control system controls the alarm to start.

[0016] It is important to note that in this technical solution, the infrared temperature probe is electrically connected to the control system via a shielded cable, collecting the battery surface temperature in real time. When the detected value exceeds a preset threshold, the control system immediately triggers an audible and visual alarm and simultaneously sends a signal to the robotic arm controller to suspend detection, thus avoiding detection errors or safety hazards in high-temperature environments. This design achieves the simultaneous integration of voltage detection and temperature monitoring. Non-contact temperature measurement technology prevents corrosion of the sensor caused by electrolyte leakage. Combined with a threshold warning mechanism, it establishes a real-time protection system for abnormal battery conditions. This system is particularly suitable for warning of thermal runaway risks during high-frequency inspections of subway batteries, enhancing the safety and reliability of the device.

[0017] A battery intelligent testing method, comprising:

[0018] Step 1: The control system triggers the inspection task according to the set time and controls the visual camera to capture the image of the battery pack;

[0019] Step 2: The control system extracts the coordinates of the first battery electrode through an image recognition algorithm and calculates the arrangement positions of the remaining battery electrodes based on preset battery size parameters;

[0020] The step 2 specifically includes the following steps:

[0021] Step 2.1: Preprocess the image to enhance the contrast of the electrode area;

[0022] The step 2.1 specifically includes the following steps:

[0023] Step 2.11: Convert the color image to grayscale image to eliminate color interference as shown below:

[0024] Gray=0.299R+0.587G+0.114B;

[0025] Step 2.12: Use Gaussian filtering to remove Gaussian noise from the image, as shown below:

[0026]

[0027] Where σ is the standard deviation of the Gaussian kernel, I(x, y) is the input image, G(x, y) is the filtered image, and the kernel size is set to 3×3 or 5×5;

[0028] Step 2.13: Use histogram equalization to improve the contrast between the electrode and the background, including:

[0029] Calculate the histogram H(k) of the grayscale image, which represents the frequency of occurrence of grayscale value k (k = 0, 1, ..., 255);

[0030] Calculate the cumulative distribution function as shown below:

[0031]

[0032] The original grayscale value is mapped to the new grayscale range through linear transformation, as shown in the following formula:

[0033]

[0034] Where, CDF min and CDF max are the minimum and maximum values of the cumulative distribution function;

[0035] Step 2.14: Perform Otsu threshold segmentation on the enhanced image, automatically determine the optimal threshold T, and convert the image into a binary image as shown below:

[0036]

[0037] The threshold T is determined by maximizing the inter-class variance, and the formula is:

[0038]

[0039] Among them, ω0, ω1 are the ratios of foreground and background pixels, and μ0, μ1 are the average grayscale values of foreground and background.

[0040] Step 2.2: Based on the preprocessed image, obtain the center coordinates of the first battery electrode in the battery pack;

[0041] The step 2.2 specifically includes the following steps:

[0042] Step 2.21: Extract the geometric features of the electrode from the preprocessed image;

[0043] Step 2.22: Based on the extracted geometric features of the electrode, the geometric shape of the electrode is fitted by the least squares method, and the center coordinates of the fitted shape are calculated as the three-dimensional center coordinates (X0, Y0, Z0) of the electrode.

[0044] Step 2.3: Based on the number of rows and columns in the battery pack and the size of a single battery, obtain the coordinates of each battery electrode in the battery pack.

[0045] The step 2.3 specifically includes the following steps:

[0046] Since the batteries in the battery pack are arranged in rows and columns, according to the three-dimensional center coordinates (X0, Y0, Z0) of the first battery electrode and the preset size of the single battery in the X and Y directions, x 、l y The distance d between the battery and the battery in the X and Y directions x d y , calculate the three-dimensional coordinates (X i，j , Y i，j , Z i，j ), since the Z coordinates of batteries on the same plane are the same, we have:

[0047] X i，j =X0+(j-1)·(l x +d x )

[0048] Y i，j =Y0+(i-1)·(l y +d y )

[0049] Z i，j =Z0

[0050] Wherein, i=1, 2, ....., m represents the row number, j=1, 2, ...., n represents the column number, and m and n are the number of rows and columns of the battery pack respectively.

[0051] Step 3: The control system generates the motion path of the robotic arm and drives the probe to contact each battery electrode in turn for detection.

[0052] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0053] 1. This invention achieves efficient and safe automated testing through a modular design consisting of "base support - robotic arm positioning - visual guidance - automatic inspection." The robotic arm's high-precision positioning and multi-dimensional flexible motion, combined with the intelligent recognition of a visual camera, can rapidly calculate the electrode coordinates of densely packed battery cells, eliminating the arduous manual labor of frequent bending and sidling.

[0054] 2. In the present invention, the double-ply clamping design significantly improves the tube body's resistance to pull-out and torsional rigidity, preventing the probe from lateral displacement due to the force exerted on the contact electrode during detection, thereby ensuring stable contact resistance during voltage detection. During disassembly, it is only necessary to reversely rotate the first plywood to loosen the clamping force, and the tube body and probe can be quickly pulled out, realizing "replacement as soon as damage occurs". This is particularly suitable for scenarios where probe loss is frequent during battery testing on subway trains. Combined with the automated operation of the robotic arm, probe replacement can be completed within 30 seconds, greatly improving maintenance efficiency.

[0055] 3. In the present invention, the supporting function of the bearing enables the probe to achieve stress-free contact through its own floating adjustment when it is quickly positioned under the drive of the robotic arm, significantly reducing the collision wear between the probe and the electrode and extending the service life.

[0056] 5. In the present invention, the intelligent battery testing method utilizes a "single electrode positioning - global coordinate calculation" design in image processing and coordinate calculation, achieving a dual improvement in detection efficiency and accuracy. During the image processing phase, preprocessing techniques such as grayscale conversion, Gaussian filtering, and histogram equalization effectively enhance the contrast of the electrode regions of densely packed batteries. During the coordinate calculation phase, the strict row and column arrangement of the battery pack is utilized, and the two-dimensional coordinates of all battery electrodes can be quickly calculated by simply locating the coordinates of the first electrode in the first image, eliminating the need for repeated image acquisition and processing for each battery. This design completely abandons the inefficient "one battery, one image" model and achieves batch generation of global coordinates through "one-time positioning + regular calculation." BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0058] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0059] Figure 2 Schematic diagram of the three-dimensional structure of the robot arm and the placement rack of the present invention;

[0060] Figure 3 Schematic diagram of the three-dimensional structure of the detection device of the present invention;

[0061] Figure 4 is a schematic diagram of the three-dimensional structure of the mounting frame of the present invention;

[0062] Figure 5 It is a schematic cross-sectional view of a portion of the mounting frame and the tube body of the present invention;

[0063] Figure 6 is a flow chart of the present invention;

[0064] Figure 7 This is a structural diagram of Example 2 of the present invention.

[0065] Among them: 1-robotic arm, 2-placing frame, 3-battery pack, 4-battery, 5-base, 6-detection device, 7-vertical plate, 8-mounting frame, 9-probe, 10-connecting frame, 11-visual camera, 12-support plate, 13-infrared temperature probe, 14-tube body, 15-first splint, 16-second splint, 17-bearing. DETAILED DESCRIPTION

[0066] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0067] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are also within the scope of protection of the present invention.

[0068] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other.

[0069] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0070] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0071] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other.

[0072] Example 1

[0073] like Figure 1-Figure 5As shown, this embodiment proposes an intelligent battery testing device, comprising a base 5 and a placement rack 2 located on one side of the base 5. The base 5 is provided with a robotic arm 1. The end of the robotic arm 1, away from the base 5, is provided with a visual camera and a detection device 6 that cooperates with the electrodes of the battery 4. The detection device 6 is used to detect the voltage and current of the battery 4. The placement rack 2 is used to place the battery pack 3. The device also includes a control system and a storage system. The control system controls the robotic arm 1 to drive the detection device 6 to test the battery 4 to be tested based on the image of the battery pack 3 captured by the visual camera. The storage system is used to store the test data. It should be noted that the intelligent battery 4 testing device adopts a modular design of "base 5 support - robotic arm 1 positioning - visual guidance - automatic detection" to achieve efficient and safe testing. The base 5 serves as the basic supporting platform and is made of high-strength steel. The bottom surface has non-slip pads or anchor bolt holes. A flange is reserved in the middle for mounting the robotic arm 1. The edges are provided with cable storage grooves and power and data communication interfaces to ensure device stability and enable signal exchange. The placement frame 2 is located on one side of the base 5. It features a frame-like structure and universal rollers with brakes at the bottom, facilitating movement and positioning. The robotic arm 1 utilizes a six-axis servo mechanism with a working radius of 1010mm and a repeatability of 0.01mm. It can rotate 360° horizontally, pitch ±90° vertically, and fine-tune the end-position by ±180°. The end is connected to the detection device 6 via a quick-release flange. A visual camera is affixed to the end of the robotic arm 1, utilizing a 2D / 3D vision solution. Its tilting lens covers the battery pack 3. The control system utilizes an Advantech industrial computer as its core hardware, with a built-in motion control card and an external touchscreen. This allows for rapid and accurate calculation of electrode coordinates and generation of collision-free trajectories. The storage system utilizes a SQL Server database for real-time storage of detection data. During operation, the visual camera captures images for preprocessing and electrode positioning. The robotic arm 1 then moves to the target position according to the calculated coordinates. The detection device 6 contacts the electrode to collect data, store it for verification, and finally, the robotic arm 1 moves the detection device 6 to the next electrode. In summary, the present invention achieves efficient and safe automated testing through a modular design consisting of "base 5 support - robotic arm 1 positioning - visual guidance - automatic inspection." The robotic arm 1, with its high-precision positioning and multi-dimensional flexible motion, combined with the intelligent recognition of a visual camera, can rapidly calculate the electrode coordinates of densely packed batteries 4, replacing the arduous manual labor of frequent bending and sidling.

[0074] like Figure 3-Figure 5As shown, in this embodiment, the end of the robotic arm 1 is provided with a vertical plate 7, and a mounting bracket 8 is provided on the vertical plate 7. A mounting hole is provided through the mounting bracket 8, and the mounting hole is vertically arranged. The detection device 6 includes a probe 9, and the probe 9 is detachably connected to the inner side of the mounting hole through a connecting device. The connecting device includes a tube body 14, and the tube body 14 passes through the mounting hole. The probe 9 is installed on the inner side of the rotating hole. A first clamping plate 15 and a second clamping plate 16 are provided on the side wall of the tube body 14 at intervals. The first clamping plate 15 is threadedly connected to the tube body 14, and the second clamping plate 16 is fixedly connected to the tube body 14. The first clamping plate 15 and the second clamping plate 16 are respectively located on both sides of the mounting hole. It should be noted that the probe 9 directly contacts the battery 4 electrode to transmit detection signals such as voltage and current. The head is usually made of a metal material with excellent conductive properties (such as gold-plated copper alloy), and the surface is treated with anti-oxidation. The connecting device adopts a "tube body 14-double plywood" detachable structural design, and the core components include the tube body 14, the first plywood 15 and the second plywood 16: the tube body 14 is a hollow cylindrical rod, which passes through the mounting hole of the mounting frame 8 in the vertical direction, and its inner wall provides an axial positioning channel for the probe 9 to ensure that the axis of the probe 9 is vertically aligned with the center of the battery 4 electrode after insertion; the outer wall of the tube body 14 is spaced apart from top to bottom by the first plywood 15 and the second plywood 16, wherein the inner wall of the first plywood 15 is provided with a thread matching the outer wall of the tube body 14, which can rotate and slide along the axial direction of the tube body 14, and the second plywood 16 is fixed to the lower part (or upper part) of the tube body 14 by interference fit or keyway, and the outer diameters of both are larger than the diameter of the mounting hole and respectively fit the upper and lower surfaces (or lower and upper surfaces) of the mounting frame 8. During assembly, the tube body 14 is passed through the mounting hole from the bottom (or top) of the mounting frame 8, and the second clamping plate 16 is pre-fixed and supports the lower surface (or upper surface) of the mounting frame 8. By rotating the first clamping plate 15 clockwise, it moves upward (or downward) along the thread of the tube body 14 and presses the upper surface (or lower surface) of the mounting frame 8. The axial clamping force generated by the thread transmission is used to rigidly fix the tube body 14 and the mounting frame 8, thereby stably constraining the probe 9 to the center position of the mounting hole. The core advantages of this structure are: through the threaded adjustment function of the first clamping plate 15, it can adapt to different mounting frames 8 with a thickness of 10mm-30mm, avoiding customized processing; the double-clamping plate clamping design significantly improves the tube body 14's anti-pullout ability and torsional stiffness, preventing the probe 9 from being laterally offset due to the force of the contact electrode during detection, ensuring stable contact resistance during voltage detection; when disassembling, only the first clamping plate 15 needs to be rotated in the opposite direction to loosen the clamping force, and the tube body 14 and the probe 9 can be quickly pulled out, realizing "replacement as soon as damage occurs", which is especially suitable for the frequent probe 9 loss scenario in the detection of subway train batteries 4. With the automated operation of the robotic arm 1, the probe 9 can be replaced within 30 seconds, greatly improving maintenance efficiency.

[0075] like Figure 3-Figure 5As shown, in this embodiment, the probe 9 is connected to the inner side of the tube body 14 via a bearing 17. It should be noted that the core of the structural design of the probe 9 being connected to the inner side of the tube body 14 via the bearing 17 is to provide an axial support bearing 17 inside the tube body 14, so that the probe 9 can slide flexibly relative to the tube body 14 while maintaining precise axial positioning. Specifically, a bearing 17 mounting groove is provided in the middle or lower end of the inner wall of the tube body 14, and a miniature bearing 17 is fixedly installed in the groove. The inner ring of the bearing 17 is interference fit with the outer side wall of the tail of the probe 9 or is connected by a keyway, and the outer ring is tightly fitted with the mounting groove of the tube body 14, forming a sliding friction pair between the probe 9 and the tube body 14. This structure allows probe 9 to slide freely up and down along the axis of tube body 14 when contacting the battery 4 electrode, adapting to the height difference of the electrode surface. Bearing 17 is typically made of corrosion-resistant stainless steel or engineering plastic (such as polytetrafluoroethylene), and the surface is lubricated to reduce friction. A dustproof seal is added to the outside of bearing 17 to prevent electrolyte mist or dust from the battery 4 testing environment from entering and affecting rotational flexibility. In this solution, the support of bearing 17 enables probe 9 to achieve stress-free contact through its own floating adjustment when quickly positioned by the robot arm 1, significantly reducing collision wear between probe 9 and the electrode and extending its service life.

[0076] like Figure 3-Figure 5 As shown, in this embodiment, a connecting frame 10 is provided on the vertical plate 7, and the visual camera 11 is mounted on the connecting frame 10. A support plate 12 is provided on one side of the vertical plate 7, and an infrared temperature probe 13 is mounted on the support plate 12, which is electrically connected to the control system. When the infrared temperature probe 13 detects that the temperature of the battery 4 exceeds a threshold, the control system activates an alarm. It should be noted that the infrared temperature probe 13 is electrically connected to the control system via a shielded cable, collecting the surface temperature of the battery 4 in real time. When the detected value exceeds a preset threshold, the control system immediately triggers an audible and visual alarm and simultaneously sends a signal to the controller of the robotic arm 1 to suspend detection, thereby avoiding detection errors or safety hazards in high-temperature environments. This design achieves the simultaneous integration of voltage detection and temperature monitoring. Non-contact temperature measurement technology prevents corrosion of the sensor caused by electrolyte leakage. Combined with a threshold warning mechanism, it establishes a real-time protection system for abnormal battery 4 conditions. This system is particularly suitable for warning of thermal runaway risks during high-frequency inspections of subway batteries 4, improving the safety and reliability of the device.

[0077] Example 2

[0078] like Figure 7 As shown, in this embodiment, a total of 6 battery packs 3 are arranged around the robotic arm 1, with two battery packs 3 in a group, distributed on the front side and left and right sides of the robotic arm. The robotic arm can detect these 6 battery packs 3 respectively. This arrangement can effectively utilize the robotic arm swing path, maximize the travel range, save energy consumption and improve work efficiency.

[0079] Example 3

[0080] like Figure 6 As shown, this embodiment proposes an intelligent testing method for a battery 4 based on the embodiment 1, including:

[0081] Step 1: The control system triggers the detection task according to the set time and controls the visual camera 11 to capture the image of the battery pack 3;

[0082] Step 2: The control system extracts the coordinates of the first battery 4 electrode through the image recognition algorithm and calculates the coordinates of the first battery 4 electrode based on the preset battery 4 size.

[0083] Inch parameters, calculate the arrangement position of the remaining 4 battery electrodes;

[0084] The step 2 specifically includes the following steps:

[0085] Step 2.1: Preprocess the image to enhance the contrast of the electrode area;

[0086] The step 2.1 specifically includes the following steps:

[0087] Step 2.11: Convert the color image to grayscale image to eliminate color interference as shown below:

[0088] Gray=0.299R+0.587G+0.114B;

[0089] Step 2.12: Use Gaussian filtering to remove Gaussian noise from the image, as shown below:

[0090]

[0091] Where σ is the standard deviation of the Gaussian kernel, I(x, y) is the input image, G(x, y) is the filtered image, and the kernel size is set to 3×3 or 5×5;

[0092] Step 2.13: Use histogram equalization to improve the contrast between the electrode and the background, including:

[0093] Calculate the histogram H(k) of the grayscale image, which represents the frequency of occurrence of grayscale value k (k = 0, 1, ..., 255);

[0094] Calculate the cumulative distribution function as shown below:

[0095]

[0096] The original grayscale value is mapped to the new grayscale range through linear transformation, as shown in the following formula:

[0097]

[0098] Where, CDF min and CDF max are the minimum and maximum values of the cumulative distribution function;

[0099] Step 2.14: Perform Otsu threshold segmentation on the enhanced image, automatically determine the optimal threshold T, and convert the image into a binary image as shown below:

[0100]

[0101] The threshold T is determined by maximizing the inter-class variance, and the formula is:

[0102]

[0103] Among them, ω0, ω1 are the ratios of foreground and background pixels, and μ0, μ1 are the average grayscale values of foreground and background.

[0104] Step 2.2: Based on the preprocessed image, obtain the center coordinates of the first battery electrode in the battery pack;

[0105] The step 2.2 specifically includes the following steps:

[0106] Step 2.21: Extract the geometric features of the electrode from the preprocessed image;

[0107] Step 2.22: Based on the extracted geometric features of the electrode, the geometric shape of the electrode is fitted by the least squares method, and the center coordinates of the fitted shape are calculated as the three-dimensional center coordinates (X0, Y0, Z0) of the electrode.

[0108] Step 2.3: Based on the number of rows and columns in the battery pack and the size of a single battery, obtain the coordinates of each battery electrode in the battery pack.

[0109] The step 2.3 specifically includes the following steps:

[0110] Since the batteries in the battery pack are arranged in rows and columns, according to the three-dimensional center coordinates (X0, Y0, Z0) of the first battery electrode and the preset size of the single battery in the X and Y directions, x 、l y The distance d between the battery and the battery in the X and Y directions x d y , calculate the three-dimensional coordinates (X i，j , Y i，j , Z i，j ), since the Z coordinates of batteries on the same plane are the same, we have:

[0111] X i，j =X0+(j-1)·(l x +dx )

[0112] Y i，j =Y0+(i-1)·(l y +d y )

[0113] Z i，j =Z0

[0114] Wherein, i=1, 2, ....., m represents the row number, j=1, 2, ...., n represents the column number, and m and n are the number of rows and columns of the battery pack respectively.

[0115] Step 3: The control system generates the motion path of the robotic arm and drives the probe to contact each battery electrode in turn for detection.

[0116] The circuits, electronic components and modules involved are all existing technologies and can be fully implemented by those skilled in the art. Needless to say, the content protected by the present invention does not involve improvements to software and methods.

[0117] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0118] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A battery intelligent testing device, characterized in that: The invention comprises a base (5) and a placement rack (2) located on one side of the base (5); a mechanical arm (1) is provided on the base (5); a visual camera (11) and a detection device (6) cooperating with the electrodes of a battery (4) are provided at one end of the mechanical arm (1) away from the base (5); the detection device (6) is used to detect the voltage and current of the battery (4); and the placement rack (2) is used to place a battery pack (3); It also includes a control system and a storage system. The control system controls the robot arm (1) to drive the detection device (6) to detect the battery (4) to be detected based on the image of the battery pack (3) captured by the visual camera. The storage system is used to store the detection data.

2. The intelligent battery testing device according to claim 1, characterized in that: The end of the mechanical arm (1) is provided with a vertical plate (7), the vertical plate (7) is provided with a mounting frame (8), the mounting frame (8) is provided with a mounting hole, and the mounting hole is vertically arranged. The detection device (6) includes a probe (9), and the probe (9) is detachably connected to the inner side of the mounting hole through a connecting device.

3. The intelligent battery testing device according to claim 1, characterized in that: The connecting device includes a tube body (14), the tube body (14) passes through the mounting hole, the probe (9) is installed on the inner side of the mounting hole, and a first clamping plate (15) and a second clamping plate (16) are sleeved on the side wall of the tube body (14), the first clamping plate (15) is threadedly connected to the tube body (14), and the second clamping plate (16) is fixedly connected to the tube body (14), and the first clamping plate (15) and the second clamping plate (16) are respectively located on both sides of the mounting hole.

4. The intelligent battery testing device according to claim 2, characterized in that: The probe (9) is connected to the inner side of the tube body (14) via a bearing (17).

5. The intelligent battery testing device according to claim 2, characterized in that: A support plate (12) is provided on one side of the vertical plate (7), and an infrared temperature probe (13) electrically connected to a control system is provided on the support plate (12). When the infrared temperature probe (13) detects that the temperature of the battery (4) exceeds a threshold value, the control system controls an alarm to start.

6. A battery intelligent testing method, implemented by the battery intelligent testing device according to claims 1-5, characterized in that: include: Step 1: The control system triggers the detection task according to the set time, and controls the visual camera (11) to capture an image of the battery pack (3); Step 2: The control system extracts the coordinates of the first battery (4) electrode through an image recognition algorithm, and calculates the arrangement positions of the remaining battery (4) electrodes based on preset battery (4) size parameters; Step 3: The control system generates a motion path for the robot arm (1) and drives the probe (9) to contact each battery (4) electrode in turn for detection.

7. The intelligent battery testing method according to claim 6, characterized in that: The step 2 specifically includes the following steps: Step 2.1: Preprocess the image to enhance the contrast of the electrode area; Step 2.2: Based on the preprocessed image, obtain the center coordinates of the first battery electrode in the battery pack; Step 2.3: According to the number of rows and columns of the battery pack (3) and the size of a single battery, the coordinates of the electrodes of each battery (4) in the battery pack (3) are obtained.

8. The intelligent battery testing method according to claim 7, characterized in that: The step 2.1 specifically includes the following steps: Step 2.11: Convert the color image to grayscale image to eliminate color interference as shown below: Gray=0.299R+0.587G+0.114B; Step 2.12: Use Gaussian filtering to remove Gaussian noise from the image, as shown below: Where σ is the standard deviation of the Gaussian kernel, I(x, y) is the input image, G(x, y) is the filtered image, and the kernel size is set to 3×3 or 5×5; Step 2.13: Use histogram equalization to improve the contrast between the electrode and the background, including: Calculate the histogram H(k) of the grayscale image, which represents the frequency of occurrence of grayscale value k (k = 0, 1, ..., 255); Calculate the cumulative distribution function as shown below: The original grayscale value is mapped to the new grayscale range through linear transformation, as shown in the following formula: Where, CDF min and CDF max are the minimum and maximum values of the cumulative distribution function; Step 2.14: Perform Otsu threshold segmentation on the enhanced image, automatically determine the optimal threshold T, and convert the image into a binary image as shown below: The threshold T is determined by maximizing the inter-class variance, and the formula is: Among them, ω0, ω1 are the ratios of foreground and background pixels, and μ0, μ1 are the average grayscale values of foreground and background.

9. The intelligent battery testing method according to claim 8, characterized in that: The step 2.2 specifically includes the following steps: Step 2.21: Extract the geometric features of the electrode from the preprocessed image; Step 2.22: Based on the extracted geometric features of the electrode, the geometric shape of the electrode is fitted by the least squares method, and the center coordinates of the fitted shape are calculated as the three-dimensional center coordinates (X0, Y0, Z0) of the electrode.

10. The intelligent battery testing method according to claim 9, characterized in that: The step 2.3 specifically includes the following steps: Since the batteries in the battery pack (3) are arranged in rows and columns, according to the three-dimensional center coordinates (X0, Y0, Z0) of the electrode of the first battery (4) and the preset size of the single battery in the X and Y directions, x 、l y The distance d between the battery and the battery in the X and Y directions x d y , calculate the three-dimensional coordinates (X i，j , Y i，j , Z i，j ), since the Z coordinates of batteries on the same plane are the same, we have: X i，j =X0+(j-1)·(l x +d x ) Y i，j =Y0+(i-1)·(l y +d y ) WITH i，j =Z0 Wherein, i=1, 2, ..., m represents the row number, j=1, 2, ..., n represents the column number, and m and n are the number of rows and columns of the battery pack respectively.

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