Defect identifying and marking system and method and computer readable storage medium

Abstract

The invention discloses a defect identification and marking system and method and a computer readable storage medium, and relates to the technical field of battery diaphragms. The defect identifying and marking system is applied to the slitting system, the slitting system comprises at least one winding roller, and each winding roller is used for winding a slit sub-roll battery diaphragm. The defect identifying and marking system comprises a defect identifying device and a marking device. And the defect identification device is used for carrying out defect detection on the sub-roll battery diaphragm which is being wound by each winding roller. And the marking device obtains the grade of the sub-roll battery diaphragm sent by the defect identification device so as to carry out grade calibration on the sub-roll battery diaphragm. Wherein the defect identification device calls work order information of a sub-roll battery diaphragm which is being rolled, and determines a rating standard of the sub-roll battery diaphragm according to the work order information; the defect identification device scans the sub-roll battery diaphragm which is being rolled to determine defect data; and judging the defect data according to a rating standard so as to determine the grade of the sub-roll battery diaphragm which is being rolled.

Description

Technical Field

[0001] The present invention relates to the technical field of battery separators, and in particular to a defect identification and marking system and method, and a computer-readable storage medium. Background Art

[0002] Lithium battery separators are a crucial component of the battery structure, and their quality directly impacts battery safety and performance. Separators are typically manufactured from polypropylene (PP) pellets through a process involving forming, stretching, and slitting, ultimately resulting in a functional membrane just a few microns thick and precisely sized. Because they play a crucial role in electrical insulation and controlling ion channels within the battery, the membrane surface must be free of critical defects before being shipped to the battery assembly stage.

[0003] In the slitting stage, the last step in diaphragm production, defect scanners are usually deployed to conduct full-scale online inspection of the diaphragm surface in order to strictly screen out products that meet quality standards.

[0004] Although current defect scanners have achieved high-precision imaging and continuous scanning in diaphragm inspection, they still have the following significant drawbacks:

[0005] Unable to automatically output defect grade determination: The current system can only detect defects but cannot automatically determine OK / NG based on defect type, location, or customer standards, requiring manual review.

[0006] Manual judgment is prone to errors: Different operators have different experiences, which can easily lead to misjudgment, missed judgment, and even the risk of defective products being mixed with good products;

[0007] Defect determination rules lack customization: Different customers have different tolerances for defects, and the existing system formulas are not capable of being customized by customer, which affects adaptation efficiency.

[0008] Long learning cycle for new employees: Due to the complexity and diversity of defect images, new employees need to go through a 7-10 day training cycle before they can start working, which results in low overall efficiency.

[0009] In summary, the current lithium battery diaphragm defect detection still relies heavily on manual intervention, and has problems such as low efficiency, high misjudgment rate, and inconsistent standards. Summary of the Invention

[0010] The main technical problem solved by the present invention is to provide an automatic and standardized defect recognition and marking system and a corresponding method.

[0011] According to a first aspect, an embodiment provides a defect identification and marking system, wherein the defect identification and marking system is applied to a slitting system for slitting battery separators, wherein the slitting system includes at least one winding roller, and each winding roller is used to rewind the slit sub-roll battery separator;

[0012] The defect identification and marking system includes:

[0013] Defect recognition device, used to detect defects in the sub-roll battery separator film being wound by each winding roller;

[0014] The defect recognition device stores work order information and corresponding rating standards of at least one sub-roll battery separator film; the defect recognition device calls the work order information of the sub-roll battery separator film being wound, and determines the rating standard of the sub-roll battery separator film being wound according to the work order information; the defect recognition device scans the sub-roll battery separator film being wound to determine defect data; the defect data is judged according to the rating standard of the sub-roll battery separator film being wound to determine the grade of the sub-roll battery separator film being wound;

[0015] The marking device is arranged on the winding roller and is used to obtain the grade of the sub-roll battery separator sent by the defect identification device to calibrate the grade of the sub-roll battery separator.

[0016] In one embodiment, the defect recognition device includes a camera and a processor;

[0017] Using the camera to collect image information of the sub-roll battery separator being wound;

[0018] The processor identifies the image information according to a preset image processing algorithm to determine the diaphragm defect, and determines the defect data according to the diaphragm defect;

[0019] Among them, the diaphragm defect includes a first defect type and a second defect type; when the diaphragm defect is the first defect type, the defect data is less than or equal to a first set value, and the processor determines that the grade of the sub-roll battery diaphragm is unqualified; when the diaphragm defect is the second defect type, the processor accumulates and stores the data information of the second defect type, and determines the defect data when the sub-roll battery diaphragm being wound is completed.

[0020] In one embodiment, the second defect type includes a first sub-defect type and a second sub-defect type;

[0021] When the sub-roll battery separator film being wound is finished winding, the first sub-defect type and the second sub-defect type are counted to determine the defect data; when the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator film is unqualified; when the defect data is greater than the first set value and less than or equal to a second set value, the processor determines that the grade of the sub-roll battery separator film is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery separator film is qualified;

[0022] or,

[0023] When the sub-roll battery diaphragm being wound is completed, only the first sub-defect type is counted to determine the defect data; when the defect data is less than or equal to the first set value, the processor determines that the grade of the sub-roll battery diaphragm is unqualified; when the defect data is greater than the first set value and less than or equal to the second set value, the processor determines that the grade of the sub-roll battery diaphragm is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery diaphragm is qualified.

[0024] In one embodiment, the processor selects any one defect type from the first defect type and the second defect type as a warning defect type according to preset requirements; when the processor detects that the diaphragm defect is the warning defect type, it outputs a warning signal and the coordinate positioning of the warning defect type.

[0025] In one embodiment, the defect recognition device further includes an encoder, which is disposed on the winding roller to determine the rotation angle and displacement of the winding roller, and output a trigger pulse according to the rotation angle and displacement;

[0026] When the camera obtains the trigger pulse, it collects image information of the sub-roll battery separator being wound;

[0027] The processor determines the coordinate location of the warning defect type according to the pixel points of the image information and the trigger pulse.

[0028] In one embodiment, when the marking device obtains the grade of the sub-roll battery separator film sent by the defect identification device, the grade is calibrated at the winding end of the sub-roll battery separator film that has been completed.

[0029] In one embodiment, after the defect identification device completes the grade determination of the sub-roll battery separator, the work order information, separator defects and grade determination results of the sub-roll battery separator are uploaded for statistical analysis.

[0030] According to a second aspect, an embodiment provides a defect identification and marking method, the defect identification and marking method being applied to a slitting system for slitting a battery separator, the slitting system comprising at least one winding roller, each winding roller being used to rewind the slit sub-roll of battery separator;

[0031] The defect identification and marking method includes:

[0032] The work order information of the sub-roll battery separator film being wound on each winding roller is called from the stored work order information of at least one sub-roll battery separator film and the corresponding rating standard;

[0033] Determining a rating standard for the sub-roll battery separator being wound according to the work order information;

[0034] Scanning the reeled battery separator to determine defect data;

[0035] The defect data is judged according to the rating standard of the sub-roll battery separator film being wound to determine the grade of the sub-roll battery separator film being wound.

[0036] In one embodiment, the defect data is judged according to the rating standard of the battery separator film sub-roll being wound to determine the grade of the battery separator film sub-roll being wound, including:

[0037] Acquiring image information of the sub-roll battery separator being wound;

[0038] Identifying the image information according to a preset image processing algorithm to determine a diaphragm defect, and determining the defect data according to the diaphragm defect;

[0039] Wherein, the diaphragm defect includes a first defect type and a second defect type, and the second defect type includes a first sub-defect type and a second sub-defect type;

[0040] When the separator defect is of the first defect type and the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator is unqualified;

[0041] When the sub-roll battery separator film being wound is finished winding, the first sub-defect type and the second sub-defect type are counted to determine the defect data; when the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator film is unqualified; when the defect data is greater than the first set value and less than or equal to a second set value, the processor determines that the grade of the sub-roll battery separator film is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery separator film is qualified;

[0042] or,

[0043] When the sub-roll battery diaphragm being wound is completed, only the first sub-defect type is counted to determine the defect data; when the defect data is less than or equal to the first set value, the processor determines that the grade of the sub-roll battery diaphragm is unqualified; when the defect data is greater than the first set value and less than or equal to the second set value, the processor determines that the grade of the sub-roll battery diaphragm is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery diaphragm is qualified.

[0044] According to a third aspect, an embodiment provides a computer-readable storage medium, on which a computer program is stored. The computer program can be executed by a processor to implement the method described in any one of the above embodiments.

[0045] According to the defect identification and marking system and method and computer-readable storage medium of the above-mentioned embodiment, the defect identification and marking system is installed in the slitting system and includes a defect identification device and a marking device. The defect identification device pre-stores work order information and corresponding grading standards for different sub-rolls of battery separator film. When a sub-roll of battery separator film is being wound, the defect identification device retrieves the work order information of the sub-roll of battery separator film to determine the grading standard for the sub-roll of battery separator film. After determining the grading standard for the sub-roll of battery separator film, the sub-roll of battery separator film is scanned to determine defect data. The defect data is then judged using the corresponding grading standard to determine the grade of the sub-roll of battery separator film. After determining the grade of the sub-roll of battery separator film, the grade is sent to the marking device, which uses the marking device to calibrate the grade of the sub-roll of battery separator film. Utilizing the defect identification and marking system and method of the present application can significantly avoid the manual judgment process, reduce human misjudgments, misclassifications, and omissions, and also improve the processing efficiency of sub-roll battery separator film grading. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 A schematic structural diagram of a slitting system in one embodiment;

[0047] Figure 2 A schematic diagram of the structure of a defect identification and marking system in one embodiment;

[0048] Figure 3 A schematic structural diagram of a defect identification device in one embodiment;

[0049] Figure 4 A method flow chart of a defect identification and marking method performed by a defect identification device in one embodiment;

[0050] Figure 5 A schematic structural diagram of a marking device in one embodiment;

[0051] Figure 6 Schematic diagram of the structure of a slitting system equipped with a defect recognition and marking system in one embodiment. DETAILED DESCRIPTION

[0052] The present invention will be further described in detail below by means of specific embodiments in conjunction with the accompanying drawings. Similar elements in different embodiments are numbered with associated similar elements. In the following embodiments, many detailed descriptions are provided to enable the present application to be better understood. However, those skilled in the art will readily appreciate that some of the features may be omitted in different circumstances, or may be replaced by other elements, materials, or methods. In some cases, some operations related to the present application are not shown or described in the specification. This is to avoid the core portion of the present application being overwhelmed by excessive descriptions, and for those skilled in the art, it is not necessary to describe these related operations in detail. They will fully understand the related operations based on the description in the specification and the general technical knowledge in the art.

[0053] In addition, the features, operations, or characteristics described in the specification may be combined in any appropriate manner to form various embodiments. Furthermore, the steps or actions in the method description may be reordered or adjusted in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided solely for the purpose of clearly describing a particular embodiment and are not intended to be mandatory, unless otherwise specified.

[0054] The serial numbers assigned to components herein, such as "first," "second," etc., are used solely to distinguish the objects being described and do not convey any sequential or technical meaning. References to "connection" and "coupling" herein, unless otherwise specified, include both direct and indirect connections (couplings).

[0055] The present application provides a defect identification and marking system 100, including a defect identification device 110 and a marking device 120. The marking device 120 is installed on the slitting system 200. The defect identification device 110 and the marking device 120 are linked together, and the judgment results are linked with the MES system, so as to perform grade evaluation and automatic marking on the sub-roll battery diaphragm that is being slit and has completed slitting. The details are explained below.

[0056] Please refer to Figure 1 In one embodiment, the slitting system 200 is a slitting system 200 for slitting battery separators, which includes an unwinding unit 210, a correction unit 220, a tension control unit 230, a slitting unit 240 and a winding unit 250.

[0057] In one embodiment, the unwinding unit 210 is used to support the mother roll battery separator and provide continuous and stable unwinding of the mother roll battery separator. The correction unit 220 is used to automatically correct the offset of the mother roll battery separator. The tension control unit 230 runs through the entire process of the unwinding unit 210, the slitting unit 240 and the rewinding unit 250 to maintain constant tension of the mother roll battery separator and the slit sub-roll battery separator during transportation to prevent film breakage or wrinkling. The slitting unit 240 is used to cut the mother roll battery separator into one or more sub-roll battery separators according to a set width. The rewinding unit 250 is used to rewind the slit sub-roll battery separator, wherein the rewinding unit 250 includes one or more rewinding rollers 251, and the number of rewinding rollers 251 is selected according to the specifications of the slitting system 200.

[0058] Please refer to Figure 2 In one embodiment, a defect identification and marking system 100 is provided, comprising a defect identification device 110 and a marking device 120. The defect identification device 110 is configured to detect defects in a sub-roll of battery separator film being wound by a winding roller 251 in a slitting system 200. The marking device 120 is disposed on the winding roller 251 in the slitting system 200 and is configured to obtain the grade of the sub-roll of battery separator film transmitted by the defect identification device 110 and to calibrate the grade of the sub-roll of battery separator film.

[0059] It should be noted that, regardless of the number of winding rollers 251 in the winding unit 250, the defect recognition device 110 will perform defect detection on the sub-roll battery separator film being wound on each winding roller 251. After completing the defect detection of the entire sub-roll battery separator film on each winding roller 251, the grade of the sub-roll battery separator film on each winding roller 251 is sent to the marking device 120. When the marking device 120 obtains the grade of the sub-roll battery separator film being wound from the defect recognition device 110, it performs grade calibration at the winding end of the sub-roll battery separator film after winding.

[0060] Please refer to Figure 3 In one embodiment, the defect recognition device 110 includes a light source 111, a camera 112, an encoder 113, a defect recognition electric control box 114 and a defect recognition main cabinet 115.

[0061] In one embodiment, the camera 112 is fixedly mounted directly above the winding roller 251, and is aligned vertically or at a certain angle with the sub-roll of battery separator film being wound on the winding roller 251. The camera 112 is used to capture image information of the surface of the sub-roll of battery separator film being wound. The camera 112 can be a line scan camera or an area array camera, and the camera 112 must be mounted in a position that ensures that its field of view completely covers the width of the sub-roll of battery separator film.

[0062] It should be noted that the sub-roll battery separator film may be one roll or multiple rolls. Regardless of how many rolls of sub-roll battery separator film there are, the field of view of the camera 112 needs to completely cover the width of all sub-roll battery separator film.

[0063] In one embodiment, light source 111 employs an LED light source to illuminate the sub-roll battery separator, contrasting the separator defects with the background for easier identification. The LED light source can select a wavelength of light, such as red, blue, or white, based on the separator material and separator defects of the sub-roll battery separator to optimize the image information captured by camera 112. Furthermore, the LED light source can also provide both projected and reflected lighting. The LED light source in defect identification device 110 can be selected based on the separator defects of the sub-roll battery separator.

[0064] It should be noted that projection lighting involves positioning an LED light source below a sub-roll of battery separator film and a camera 112 above the sub-roll to identify foreign matter or holes within the film. Reflection lighting involves positioning an LED light source on the same side of the camera 112 to identify surface defects within the sub-roll of battery separator film, such as scratches, creases, and oil stains.

[0065] In one embodiment, the encoder 113 is a position and speed sensor mounted on a rotating component that moves synchronously with the sub-roll of battery separator film, such as the winding roller 251, to determine the rotation angle and displacement of the winding roller 251. As the sub-roll of battery separator film moves, the winding roller 251 rotates, causing the encoder 113 to output a continuous pulse signal. The camera 112 captures image information of the winding sub-roll of battery separator film according to the trigger pulses output by the encoder 113, ensuring that the image information is not distorted or misaligned.

[0066] It should be noted that the camera 112 does not capture the image information of the sub-roll battery separator film one picture at a time, but scans it line by line. If the shooting frequency of the camera 112 does not match the winding speed of the sub-roll battery separator film, it will cause image stretching (shooting too fast), image shrinkage (shooting too slow), or image frame skipping. Therefore, the camera 112 must capture the image information of the sub-roll battery separator film according to the winding speed of the sub-roll battery separator film. The encoder 113 obtains the rotation angle and displacement of the winding roller 251 and converts it into continuous trigger pulses. Every time the camera 112 receives a fixed number of trigger pulses, it captures a line or a frame of image information. In this way, even if the image information of the sub-roll battery separator film is accelerated or decelerated, the shooting interval of the camera 112 can be automatically adjusted to ensure that the image information can truly restore the position and morphology of the sub-roll battery separator film.

[0067] In one embodiment, the defect recognition electrical control box 114 is responsible for the electrical control and on-site signal processing of the defect recognition device 110, and its main functions include power supply and power management, light source control, I / O control, encoder signal processing and safety protection. Power supply and power management refers to the distribution and management of power supply to components such as LED light sources, cameras 112, encoders 113 and fans, usually including multiple voltages such as 24V, 12V and 5V. Light source control refers to controlling the switching, brightness adjustment and triggering mode of the LED light source. I / O control refers to processing input and output signals from the production line PLC, sensors, and cameras 112 of the slitting system 200, such as warning signals and marking signals. Encoder signal processing refers to receiving encoder 113 pulses and converting them into speed data or position data for synchronization with the camera 112. Safety protection refers to integrating electrical protection mechanisms such as overcurrent protection, short circuit protection and emergency stop.

[0068] In one embodiment, the defect identification main cabinet 115 includes a memory and a processor, and the memory stores work order information of at least one sub-roll of battery separator and corresponding rating standards.

[0069] It should be noted that, based on the acceptance criteria of different customers for membrane defects of different sub-roll battery separators, the work order information of the corresponding sub-roll battery separator is established in the memory, and the corresponding formula is formulated based on the work order information, and the rating standard of the sub-roll battery separator is set in the formula. Among them, the formula and the rating standard can be added, deleted and modified to achieve the update and maintenance of the formula and the rating standard. In each production of the slitting system 200, it is necessary to create a new work order information of the sub-roll battery separator to be slit in the memory, so that when the winding roller 251 winds the sub-roll battery separator, the work order information of the sub-roll battery separator can be called to determine the rating standard, thereby performing the grade judgment of the sub-roll battery separator.

[0070] Please refer to Figure 4 In one embodiment, the processor in the defect recognition main cabinet 115 executes a defect recognition and marking method based on the work order information of the sub-roll battery separator stored in the memory to achieve grade evaluation of the slit sub-roll battery separator, which specifically includes the following steps.

[0071] Step S10: calling the work order information of the sub-roll battery separator film being wound on each winding roller, and determining the rating standard of the sub-roll battery separator film being wound according to the work order information.

[0072] In one embodiment, when the winding roller 251 starts to wind the sub-roll of battery separator film, the processor calls the work order information of the sub-roll of battery separator film and determines the rating standard of the sub-roll of battery separator film according to the work order information.

[0073] It should be noted that no matter how many sub-rolls of battery separator film are wound up by the winding roller 251 in the slitting system 200, the rating standards of the sub-rolls of battery separator film slit from the same mother roll of battery separator film are the same.

[0074] Step S20: Scan the sub-roll of battery separator being wound to determine defect data.

[0075] In one embodiment, after determining the rating standard of the sub-roll battery diaphragm, the camera 112 is used to collect image information of the sub-roll battery diaphragm being wound, and the processor identifies the image information according to a preset image processing algorithm to determine the diaphragm defects, and determines the defect data of the sub-roll battery diaphragm based on the diaphragm defects.

[0076] In one embodiment, after acquiring image information, the processor preprocesses the image information, specifically including image denoising, contrast enhancement, edge detection and sharpening, grayscale processing, and geometric correction. Image denoising uses a filtering algorithm to remove background interference and image noise; contrast enhancement is used to improve the boundary clarity of the sub-roll battery separator; edge detection and sharpening highlight the edges of separator defects, enhancing the discriminative ability of the image processing algorithm; grayscale processing simplifies the content structure of the image information, improving the analysis efficiency of the image processing algorithm; finally, perspective and distortion correction are performed on the image information based on the installation angle of the camera 112 and the light source deviation of the LED light source.

[0077] In one embodiment, after preprocessing the image information, the processor uses deep learning as a preset image processing algorithm to identify the image information. In deep learning, a convolutional neural network or a YOLO model is used to automatically identify diaphragm defects in the image information, thereby determining defect data.

[0078] In one embodiment, the processor uses an image processing algorithm to identify image information and outputs the membrane defect, the defect size, and a captured image of the membrane defect. The membrane defect includes black spots, pinholes, creases, impurities, and foreign matter, and the defect size includes dimensional information such as the width, length, and area of ​​the membrane defect.

[0079] In one embodiment, based on different customers' acceptance criteria for membrane defects of different sub-roll battery membranes, membrane defects are divided into a first defect type and a second defect type, wherein the first defect type is a fatal defect and the second defect type is a non-fatal defect; the second defect type includes a first sub-defect type and a second sub-defect type, wherein the first sub-defect type is a general defect and the second sub-defect type is a qualified defect.

[0080] It should be noted that, based on different customers' acceptance criteria for separator defects in different sub-rolls of battery separators, one or more separator defects can be selected as the first defect type. The second defect type can be assigned a score based on the size of the separator defect. Defect data is calculated using a deduction system, with an initial score set. When a separator defect is encountered in a sub-roll of battery separators, the score for the corresponding defect type is subtracted from the initial score to determine the defect data.

[0081] Step S30: Determine the defect data according to the rating standard of the battery separator sub-roll being wound to determine the grade of the battery separator sub-roll being wound.

[0082] In one embodiment, if the processor detects that the membrane defect occurring in the sub-roll battery separator is of the first defect type, the defect data will be directly less than the first set value, and the grade of the sub-roll battery separator will be directly determined to be unqualified. If the processor detects that the membrane defect occurring in the sub-roll battery separator is of the first sub-defect type and the second sub-defect type, the scores corresponding to the first sub-defect type and the second sub-defect type are counted. When the sub-roll battery separator is wound up, the defect data of the sub-roll battery separator is obtained by subtracting the counted scores corresponding to the first sub-defect type and the second sub-defect type from the initial score. If the defect data is less than the first set value, the processor determines that the grade of the sub-roll battery separator is unqualified; if the defect data is greater than the first set value and less than the second set value, the processor determines that the grade of the sub-roll battery separator is pending; if the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery separator is qualified.

[0083] It should be noted that since the second sub-defect data is a qualified defect, when the defect data is counted, the second sub-defect type can be included in the defect data statistics or not. Whether the second sub-defect type is included in the statistics can be further configured according to user needs.

[0084] For example, this application sets the initial score to 100 points, and the score of the first defect type is 100 points. If the processor detects that the membrane defect of the sub-roll battery separator is the first defect type, the defect data will directly become 0 points, and the grade of the sub-roll battery separator will be directly determined to be unqualified. When the sub-roll battery separator is wound, if the cumulative defect data is less than or equal to 60, the processor determines that the grade of the sub-roll battery separator is unqualified; if the cumulative defect data is greater than 60 and less than or equal to 80, the processor determines that the grade of the sub-roll battery separator is pending; if the cumulative defect data is greater than 80, the processor determines that the grade of the sub-roll battery separator is qualified.

[0085] In one embodiment, to further improve the pass rate of sub-roll battery separators, one of the first and second defect types can be selected as a warning defect type based on preset requirements. Upon detecting a warning defect type, the processor outputs a warning signal and the coordinates of the warning defect type, allowing the operator to address the warning defect type. This minimizes the number of separator defects in the sub-roll battery separators and improves the pass rate of the sub-roll battery separators.

[0086] It should be noted that the first defect type and the second defect type may include multiple different diaphragm defects. Therefore, when selecting the warning defect type from the first defect type and the second defect type, you can select one diaphragm defect from the first defect type or the second defect type as the warning defect type, or you can select multiple diaphragm defects from the first defect type or the second defect type as the warning defect type.

[0087] In one embodiment, the coordinate location of the warning defect type may be determined based on the pixel points of the image information in the camera 112 and the trigger pulse.

[0088] Specifically, each pixel in the sub-roll of battery separator film captured by camera 112 represents the actual length unit of the sub-roll, known as the pixel pitch. Assuming the image information of the sub-roll of battery separator film captured by camera 112 is 4096 pixels wide with a pixel pitch of 10 μm / pixel, and the warning defect type appears at the 1000th pixel in the image information, the horizontal coordinate of the warning defect type can be determined using 1000×10. After determining the horizontal coordinate of the warning defect type, the actual physical horizontal coordinate of the warning defect type is then determined through camera 112 calibration.

[0089] Combined with the number of trigger pulses output by encoder 113 and the shaft diameter of the rotating component of encoder 113 that moves synchronously with the sub-roll of battery separators, the actual distance traveled by the sub-roll of battery separators can be calculated. Each time camera 112 captures a frame of image information, the corresponding encoder 113 accumulates displacement. When a warning defect type appears in that frame of image information, the accumulated actual distance traveled for that frame of image information is recorded to determine the actual physical vertical coordinate of the warning defect type.

[0090] In summary, when the winding roller 251 completes winding the sub-roll battery diaphragm being wound, the defect identification device 110 also immediately completes the grade determination of the sub-roll battery diaphragm. At this time, the marking device 120 obtains the grade of the sub-roll battery diaphragm sent by the defect identification device 110, and performs grade calibration at the winding end of the sub-roll battery diaphragm that has completed winding.

[0091] Furthermore, after completing the grade determination of the sub-roll battery separator film, the defect identification device 110 adds the grade determination result to the work order information of the sub-roll battery separator film. The defect identification device 110 can be linked with the Manufacturing Execution System (MES), an intermediate management system that connects the enterprise planning layer and the workshop execution layer, to upload the work order information of the sub-roll battery separator film to the MES system via the local area network. After reading the work order information, the MES system automatically locks the data of the unqualified sub-roll battery separator film corresponding to the fatal defect and executes a forced offline operation, that is, prohibiting the sub-roll battery separator film from flowing to the next process, while the remaining qualified sub-roll battery separator film can flow normally.

[0092] It should be noted that the work order information of the sub-roll battery separator may include the machine number, the roll number of the sub-roll battery separator, the defect type of the separator defect of the sub-roll battery separator, the grade judgment result of the sub-roll battery separator, the production time of the sub-roll battery separator and the product type of the sub-roll battery separator.

[0093] Please refer to Figure 5 In one embodiment, the marking device 120 includes a marking module 121 , a marking stamp 122 , a safety light grid 123 and a marking electric control cabinet 124 .

[0094] In one embodiment, the marking module 121 is used to move the marking stamp 122 to a specified position and perform the marking action to ensure that the membrane defects are accurately marked on the sub-roll battery separator. The marking module 121 includes a transverse motor, a longitudinal motor, and a marking actuator. The transverse motor controls the movement of the marking stamp 122 along the width of the sub-roll battery separator to achieve transverse positioning. The longitudinal motor controls the vertical movement of the marking stamp 122 to complete the vertical marking action. The marking actuator is a pneumatic cylinder or electric push rod that drives the marking stamp 122 downward to press on the sub-roll battery separator to mark.

[0095] It should be noted that both the transverse motor and the longitudinal motor use servo motors, and the longitudinal motor adopts torque mode control. When the torque of the longitudinal motor reaches the set torque, the longitudinal motor stops running to avoid the scrapping of the sub-roll battery diaphragm.

[0096] In one embodiment, the number of marking modules 121 corresponds to the number of winding rollers 251 in the slitting system 200. The winding rollers 251 in this application include two winding rollers, so the marking modules 121 provided in this application include two sets of marking modules. The two sets of marking modules in this application have a lateral movement spacing of 1400 mm to cover the width of the sub-roll battery separator film. The longitudinal distance from the 3-inch slip shaft ranges from 35 mm to 140 mm, meaning the longitudinal distance can be adjusted within a range of 35 mm to 140 mm to accommodate various specifications of sub-roll battery separator film on the slip shaft.

[0097] It should be noted that the same mother roll of battery separator film can be cut into multiple sub-rolls of different specifications. The number of sub-rolls of each specification can be set according to user needs. Regardless of the number of sub-rolls of each specification, the marking module 121 can control the marking stamp 122 to move to each sub-roll of battery separator film, so as to mark the grade within ±3mm in the middle of the sub-roll of battery separator film, and the marking is clear and complete.

[0098] In one embodiment, the marking stamp 122 includes a qualified stamp, an unqualified stamp, and a pending stamp. The marking module 121 controls the corresponding marking stamp 122 to move to the sub-roll battery diaphragm according to the grade of the corresponding sub-roll battery diaphragm to calibrate the grade of the sub-roll battery diaphragm as qualified, unqualified, or pending.

[0099] Please refer to Figure 6 In one embodiment, a safety protection device must be configured in the marking device 120. The safety protection device of the present application adopts a safety grating 123. The safety grating 123 is used to realize real-time detection of dangerous areas. Once a person or object enters the dangerous area, the cutting system 200 will immediately alarm and stop running, so as to ensure the safety of personnel and avoid accidents such as pinching, accidental touch and collision.

[0100] In one embodiment, the safety light curtain 123 is positioned to cover the entire operating area corresponding to the marking module 121, forming a longitudinal personal protection light curtain. This position effectively monitors the operator's hand or body from entering the marking area, ensuring that if an operator approaches the danger zone during operation of the slitting system 200, an alarm is immediately triggered or the equipment is shut down, thereby ensuring personnel safety.

[0101] In one embodiment, the marking electric control cabinet 124 is responsible for the power supply management, I / O signal control, PLC control unit and safety interlock control of the marking device 120. The marking device 120 is equipped with power supply modules at various levels, which are responsible for providing stable power supply to the motor and safety grating 123 in the marking module 121, such as 24V DC voltage and 220V AC voltage. The input signals of the receiving camera 112 and the defect recognition device 110 are controlled by I / O signals to control the marking stamp 122 for marking. The PLC control unit executes all automated control logic, such as: receiving grade evaluation, controlling the horizontal and vertical movement of the marking module 121, and linking with the main control cabinet. The safety interlock control is connected to the safety grating 123. When the safety grating 123 detects that a person has entered the danger zone, the PLC control unit immediately executes the interruption of the marking action or the emergency stop operation.

[0102] It should be noted that the marking module 121, marking stamp 122 and safety grating 123 in the marking device 120 can be controlled manually or automatically, can display the I / O status, and have an alarm prompt function to facilitate rapid repair of faults.

[0103] In one embodiment, after the slitting system 200 completes the winding of a sub-roll of battery separator film, it stops operating. At this point, the defect recognition device 110 has completed the grade assessment of the sub-roll of battery separator film and activates the marking device. The defect recognition device 110 and the marking device 120 are connected via an industrial Ethernet switch. After the defect recognition device 110 completes the grade assessment of each sub-roll of battery separator film, it transmits the grade assessment to the marking device 120 via the network communication of the industrial Ethernet switch. After the marking device 120 obtains the grade assessment of the corresponding sub-roll of battery separator film, it controls the movement of the marking module 121 to control the marking stamp 122 to calibrate the grade of the corresponding sub-roll of battery separator film.

[0104] In another embodiment, a defect identification and marking method is also provided. The defect identification and marking method uses the processor of the defect identification device 110 as the execution body to execute the defect identification and marking method. Since the defect identification and marking method has been clearly explained in the above embodiment, it will not be repeated here.

[0105] In a specific embodiment, the defect identification and marking system 100 and method provided in this application can achieve an automatic judgment accuracy rate of ≥99.5% for fatal defects, an automatic judgment accuracy rate of ≥95% for general defects, and an automatic judgment accuracy rate of ≤5% for the battery separator to be wound.

[0106] Those skilled in the art will appreciate that all or part of the functions of the various methods in the above embodiments can be implemented by hardware or by computer program. When all or part of the functions in the above embodiments are implemented by computer program, the program can be stored in a computer-readable storage medium, and the storage medium can include: read-only memory, random access memory, disk, optical disk, hard disk, etc., and the program is executed by a computer to implement the above functions. For example, the program is stored in the memory of the device, and when the program in the memory is executed by the processor, all or part of the above functions can be implemented. In addition, when all or part of the functions in the above embodiments are implemented by computer program, the program can also be stored in a storage medium such as a server, another computer, disk, optical disk, flash disk or mobile hard disk, and saved in the memory of the local device by downloading or copying, or the system of the local device is updated. When the program in the memory is executed by the processor, all or part of the functions in the above embodiments can be implemented.

[0107] The above examples are used to illustrate the present invention, which are only used to help understand the present invention and are not intended to limit the present invention. Those skilled in the art can make several simple deductions, modifications or substitutions based on the concept of the present invention.

Claims

1. A defect identification and marking system, characterized in that: The defect recognition and marking system is applied to a slitting system for slitting battery separators, wherein the slitting system includes at least one winding roller, and each winding roller is used to rewind the slit sub-roll battery separator; The defect identification and marking system includes: Defect recognition device, used to detect defects in the sub-roll battery separator film being wound by each winding roller; The defect recognition device stores work order information and corresponding rating standards of at least one sub-roll battery separator film; the defect recognition device calls the work order information of the sub-roll battery separator film being wound, and determines the rating standard of the sub-roll battery separator film being wound according to the work order information; the defect recognition device scans the sub-roll battery separator film being wound to determine defect data; the defect data is judged according to the rating standard of the sub-roll battery separator film being wound to determine the grade of the sub-roll battery separator film being wound; The marking device is arranged on the winding roller and is used to obtain the grade of the sub-roll battery separator sent by the defect identification device to calibrate the grade of the sub-roll battery separator.

2. The defect recognition and marking system according to claim 1, wherein: The defect recognition device includes a camera and a processor; Using the camera to collect image information of the sub-roll battery separator being wound; The processor identifies the image information according to a preset image processing algorithm to determine the diaphragm defect, and determines the defect data according to the diaphragm defect; Among them, the diaphragm defect includes a first defect type and a second defect type; when the diaphragm defect is the first defect type, the defect data is less than or equal to a first set value, and the processor determines that the grade of the sub-roll battery diaphragm is unqualified; when the diaphragm defect is the second defect type, the processor accumulates and stores the data information of the second defect type, and determines the defect data when the sub-roll battery diaphragm being wound is completed.

3. The defect recognition and marking system according to claim 2, wherein: The second defect type includes a first sub-defect type and a second sub-defect type; When the sub-roll of battery separator film being wound is completed, counting the first sub-defect type and the second sub-defect type to determine the defect data; When the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator is unqualified; when the defect data is greater than the first set value and less than or equal to a second set value, the processor determines that the grade of the sub-roll battery separator is pending; When the defect data is greater than a second set value, the processor determines that the grade of the sub-roll battery separator is qualified; or, When the sub-roll of battery separator film being wound is completed, only the first sub-defect type is counted to determine the defect data; When the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator is unqualified; when the defect data is greater than the first set value and less than or equal to a second set value, the processor determines that the grade of the sub-roll battery separator is pending; When the defect data is greater than a second set value, the processor determines that the grade of the sub-roll battery separator is qualified.

4. The defect recognition and marking system according to claim 3, wherein: The processor selects any one of the first defect type and the second defect type as a warning defect type according to preset requirements; when the processor detects that the diaphragm defect is the warning defect type, it outputs a warning signal and the coordinate location of the warning defect type.

5. The defect recognition and marking system according to claim 4, wherein: The defect recognition device further includes an encoder, which is arranged on the winding roller to determine the rotation angle and displacement of the winding roller and output a trigger pulse according to the rotation angle and displacement; When the camera obtains the trigger pulse, it collects image information of the sub-roll battery separator being wound; The processor determines the coordinate location of the warning defect type according to the pixel points of the image information and the trigger pulse.

6. The defect recognition and marking system according to claim 1, wherein: When the marking device obtains the grade of the sub-roll battery separator film sent by the defect identification device, the grade is calibrated at the winding end of the sub-roll battery separator film that has been completed.

7. The defect recognition and marking system according to claim 1, wherein: After the defect identification device completes the grade determination of the sub-roll battery separator, the work order information, separator defects and grade determination results of the sub-roll battery separator are uploaded for statistical analysis.

8. A defect identification and marking method, characterized in that: The defect identification and marking method is applied to a slitting system for slitting battery separators, wherein the slitting system includes at least one winding roller, and each winding roller is used to rewind the slit sub-roll battery separator; The defect identification and marking method includes: The work order information of the sub-roll battery separator film being wound on each winding roller is called from the stored work order information of at least one sub-roll battery separator film and the corresponding rating standard; Determining a rating standard for the sub-roll battery separator being wound according to the work order information; Scanning the reeled battery separator to determine defect data; The defect data is judged according to the rating standard of the sub-roll battery separator film being wound to determine the grade of the sub-roll battery separator film being wound.

9. The defect identification and marking method according to claim 8, wherein: The defect data is judged according to the rating standard of the sub-roll battery separator film being wound to determine the grade of the sub-roll battery separator film being wound, including: Acquiring image information of the sub-roll battery separator being wound; Identifying the image information according to a preset image processing algorithm to determine a diaphragm defect, and determining the defect data according to the diaphragm defect; Wherein, the diaphragm defect includes a first defect type and a second defect type, and the second defect type includes a first sub-defect type and a second sub-defect type; When the separator defect is of the first defect type and the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator is unqualified; When the sub-roll battery separator film being wound is finished winding, the first sub-defect type and the second sub-defect type are counted to determine the defect data; when the defect data is less than or equal to a first set value, the processor determines that the grade of the sub-roll battery separator film is unqualified; when the defect data is greater than the first set value and less than or equal to a second set value, the processor determines that the grade of the sub-roll battery separator film is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery separator film is qualified; or, When the sub-roll battery diaphragm being wound is completed, only the first sub-defect type is counted to determine the defect data; when the defect data is less than or equal to the first set value, the processor determines that the grade of the sub-roll battery diaphragm is unqualified; when the defect data is greater than the first set value and less than or equal to the second set value, the processor determines that the grade of the sub-roll battery diaphragm is pending; when the defect data is greater than the second set value, the processor determines that the grade of the sub-roll battery diaphragm is qualified.

10. A computer-readable storage medium, characterized in that A computer program is stored on the medium, and the computer program can be executed by a processor to implement the method according to any one of claims 8 to 9.

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