High-precision automatic detection equipment and method for collapse amount of upper cover of battery pack of new energy automobile

Abstract

The invention discloses high-precision automatic detection equipment and method for the collapse amount of an upper cover of a battery pack of a new energy automobile. The equipment comprises a rack, a detection platform, a profiling positioning block, a pressing mechanism, an operation unit and a pneumatic displacement sensor. The sensor consists of a fixed seat, a pneumatic unit and a contact piece with a magnet, wherein the magnet is adsorbed and fixed with a steel block on the fixed seat. The method comprises the following steps: matching and positioning the upper cover of the battery pack through the profiling positioning block, acquiring product identity information by the code scanning unit, clamping a workpiece by the pressing mechanism, enabling a contact piece of the pneumatic displacement sensor to be in contact with the surface of the upper cover, converting the sinking amount into an air pressure signal and detecting, and finally binding and storing the sinking amount and the identity information. According to the invention, rapid workpiece positioning, stable clamping and high-precision detection are realized, and the requirements of battery pack upper cover collapse amount full detection and data tracing in automatic production are met.

Description

Technical Field

[0001] This invention belongs to the field of battery testing equipment technology, specifically relating to a high-precision automatic testing device and method for the sagging of the top cover of a new energy vehicle battery pack. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the safety and reliability of power batteries, as core components, have increasingly become a focus of attention. The flatness of the battery pack cover—especially the "sag" in the central area—is a critical structural component that significantly impacts overall performance. If the sagging exceeds the design allowable range, it will not only weaken the sealing effect but may also cause a decrease in structural strength and insufficient module assembly precision, leading to a series of safety hazards such as sealing failure, short circuits, and water ingress. Therefore, strictly controlling the flatness of the battery pack cover is a crucial step in ensuring the long-term stable operation of the battery system.

[0003] In the manufacturing process of battery pack covers, the detection of sag has become an indispensable quality control step. Currently, common inspection methods for the flatness of sheet metal and plastic parts in the industry mainly include: manual caliper / feeler gauge measurement: simple to operate, but inefficient, subjective, and difficult to guarantee accuracy, making it difficult to meet the high-speed requirements of large-scale production; coordinate measuring machine (CMM): has the advantage of high precision, but the equipment cost is high, the inspection speed is slow, and the requirements for the operating environment are harsh. It is usually only used for offline sampling inspection and cannot achieve full inspection coverage; laser scanner / visual measurement system: is a non-contact measurement method with a relatively fast speed, but the equipment cost is high, and the measurement stability is easily affected by environmental interference on reflective surfaces or complex feature scenarios.

[0004] Against this backdrop, the industry urgently needs a specialized automated testing equipment that can be integrated into the production line, has high testing efficiency, reliable accuracy, moderate cost, and can achieve full inspection coverage, in order to make up for the shortcomings of existing testing methods and meet increasingly stringent quality control requirements. Summary of the Invention

[0005] The purpose of this invention is to provide a high-precision automatic detection device and method for the under-collapse of the battery pack cover of a new energy vehicle, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a high-precision automatic detection device for the under-cab of a new energy vehicle battery pack cover, comprising a frame, on which a detection platform is fixedly mounted, and on which a pneumatic displacement sensor, a contour positioning block, a clamping mechanism, and an operating unit are fixedly mounted. The pneumatic displacement sensor includes a fixed base, a pneumatic unit, and a contact element. A steel block is fixedly mounted on the fixed base, and a magnet is fixedly mounted on the contact element. The magnet attracts and fixes the steel block. The clamping mechanism is located beside the contour positioning block, and the operating unit includes an industrial control unit and a barcode scanning unit.

[0007] Preferably, the pneumatic displacement sensors are arranged in a rectangular array.

[0008] Preferably, a movable frame is fixedly installed at the bottom of the frame, and the movable frame is fixedly installed with casters.

[0009] Preferably, the testing platform is fixedly equipped with a lifting assembly, which includes a first cylinder and a support plate, and the drive end of the first cylinder is fixedly connected to the support plate.

[0010] Preferably, the pressing mechanism includes a second cylinder and a pressing block, the driving end of the second cylinder is fixedly connected to the pressing block, and the pressing block is fixedly equipped with an adjustable pressing rod.

[0011] Preferably, the testing platform is fixedly equipped with a convenient control panel, which has multiple buttons.

[0012] Preferably, the rack is fixedly mounted with a cabinet, and the four corners of the testing platform are fixedly equipped with lifting lugs.

[0013] A high-precision automatic detection method for the under-sag of the top cover of a new energy vehicle battery pack, comprising the detection device as described in claims 1-7, including the step of: S1: adjusting the position and height of the contour positioning block to match the shape of the top cover of the battery pack to be detected;

[0014] S2: Place the top cover of the battery pack to be tested on the testing platform and couple and fix it with the contour positioning block;

[0015] S3: The scanning unit scans the QR code or barcode on the cover of the battery pack to be tested to obtain the product's identity information;

[0016] S4: Activate the clamping mechanism, which, together with the contour positioning block, clamps and fixes the top cover of the battery pack to be tested. The contact of the pneumatic displacement sensor contacts the surface of the top cover of the battery pack to be tested. The sinking area of ​​the top cover of the battery pack to be tested acts on the contact, and the contact transmits the sinking action to the pneumatic unit to detect the sinking amount of the top cover of the battery pack to be tested. This sinking amount is bound to and stored with the identity information.

[0017] Preferably, the method further includes automatically executing step S4 after the scanning unit successfully scans the QR code or barcode.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] This invention achieves rapid and precise workpiece positioning by physically coupling the contour positioning block with the cover to be inspected. Subsequently, a clamping mechanism firmly clamps the workpiece, eliminating measurement errors caused by workpiece vibration or displacement during the inspection process. The core pneumatic displacement sensor directly contacts the area to be measured on the cover through its magnetically fixed contact piece, accurately converting the microscopic collapse deformation into changes in air pressure signals. The pneumatic unit captures and calculates the precise collapse value. The entire inspection process is controlled by the operation unit and automatically associates product identity information through a barcode scanning unit, ultimately binding and storing the collapse data with the product identity information. This integrated solution provides a high-efficiency, high-precision, low-cost solution capable of full inspection and data traceability, effectively overcoming the limitations of existing inspection methods in terms of efficiency, accuracy, cost, and coverage. It meets the stringent requirements of 100% online control of key dimensions in the large-scale automated production of power batteries.

[0020] This invention relates to a precision detection system that integrates a contour positioning block, a cylinder clamping mechanism, and a pneumatic displacement sensor. A magnet mounted at one end of the contact element stably attracts a steel block fixed to the sensor mounting base. This design provides a uniform and gapless preload to the contact element, ensuring a constant stress state. During detection, the piston structure of the pneumatic displacement sensor extends and lifts the contact element, bringing it into contact with the battery pack cover. The pneumatic displacement sensor calculates the sagging amount of the battery pack cover based on the extension of the piston structure. The industrial control unit runs various embedded control programs (such as signal linearization calibration and tolerance judgment algorithms) to simultaneously process the air pressure signal and product information collected by the barcode scanning unit, thereby outputting accurate and traceable sagging amount detection results. This achieves a high-precision fusion of magnetic stability and contact-based pneumatic-electric conversion principle in automated detection. Attached Figure Description

[0021] Figure 1 This is the first perspective structural view of the present invention.

[0022] Figure 2 This is the second perspective structural view of the present invention.

[0023] Figure 3 This is a structural view of the pneumatic displacement sensor of the present invention.

[0024] Figure 4 This is an exploded structural view of the pneumatic displacement sensor of the present invention.

[0025] Figure 5 This is a structural view of the supporting component of the present invention.

[0026] Figure 6 This is a structural view of the clamping mechanism of the present invention.

[0027] The diagram shows: 1. Frame; 2. Detection platform; 3. Pneumatic displacement sensor; 4. Contouring positioning block; 5. Pressing mechanism; 6. Operating unit; 7. Fixed base; 8. Pneumatic unit; 9. Contact element; 10. Steel block; 11. Magnet; 12. Industrial control unit; 13. Scanning unit; 14. Movable frame; 15. Roller; 16. Lifting assembly; 17. First cylinder; 18. Support plate; 19. Second cylinder; 20. Pressing block; 21. Adjustable pressure rod; 22. Convenient control panel; 23. Button; 24. Cabinet; 25. Lifting lug. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example 1:

[0030] This invention provides a high-precision automatic detection device for the under-collapse of a new energy vehicle battery pack cover, comprising a frame 1, on which a detection platform 2 is fixedly mounted. The detection platform 2 is fixedly mounted with pneumatic displacement sensors 3, contour positioning blocks 4, a clamping mechanism 5, and an operating unit 6. The pneumatic displacement sensor 3 includes a fixed base 7, a pneumatic unit 8, and a contact element 9. A steel block 10 is fixedly mounted on the fixed base 7, and a magnet 11 is fixedly mounted on the contact element 9. The magnet 11 attracts and fixes the steel block 10. The clamping mechanism 5 is located beside the contour positioning block 4. The operating unit 6 includes an industrial control unit 12 and a barcode scanning unit 13. The pneumatic displacement sensors 3 are arranged in a rectangular array. A movable frame 14 is fixedly mounted at the bottom of the frame 1, and rollers 15 are fixedly mounted on the movable frame 14. A lifting assembly 16 is fixedly mounted on the detection platform 2, and the lifting assembly 16 includes a first cylinder 17 and a support plate 18. The drive end of the first cylinder 17 is fixedly connected to the support plate 18. The clamping mechanism 5 includes a second cylinder 19 and a pressure block 20. The drive end of the second cylinder 19 is fixedly connected to the pressure block 20, and the pressure block 20 is fixedly equipped with an adjustable pressure rod 21. The testing platform 2 is fixedly equipped with a convenient control panel 22, which is equipped with multiple buttons 23. The frame 1 is fixedly equipped with a cabinet 24, and the four corners of the testing platform 2 are fixedly equipped with lifting lugs 25.

[0031] A high-precision automatic detection method for the under-sag of a battery pack cover of a new energy vehicle, including the detection device of claims 1-7, comprising the steps of: S1: adjusting the position and height of the contour positioning block 4 to match the shape of the battery pack cover to be detected;

[0032] S2: Place the top cover of the battery pack to be tested on the testing platform 2 and couple and fix it with the contour positioning block 4;

[0033] S3: The scanning unit 13 scans the QR code or barcode on the cover of the battery pack to be tested to obtain the product's identity information;

[0034] S4: The clamping mechanism 5 is activated, and in conjunction with the contour positioning block 4, the top cover of the battery pack to be tested is clamped and fixed. The contact element 9 of the pneumatic displacement sensor 3 contacts the surface of the top cover of the battery pack to be tested. The sinking area of ​​the top cover of the battery pack to be tested acts on the contact element 9, and the contact element 9 transmits the sinking action to the pneumatic unit 8, detecting the sinking amount of the top cover of the battery pack to be tested. This sinking amount is bound to and stored with identity information. S4 is also automatically executed after the barcode scanning unit 13 successfully scans a QR code or barcode.

[0035] Through the above technical solution, this invention achieves rapid and accurate workpiece positioning by physically coupling the contour positioning block 4 with the cover to be inspected. Subsequently, the clamping mechanism 5 firmly clamps the workpiece, eliminating measurement errors caused by workpiece vibration or displacement during the inspection process. The core pneumatic displacement sensor 3 directly contacts the area to be measured on the cover through its magnetically fixed contact 9, accurately converting the microscopic collapse deformation into changes in air pressure signals. The pneumatic unit 8 captures and calculates the precise collapse value. The entire inspection process is controlled by the operation unit 6 and automatically associates product identity information through the barcode scanning unit 13, ultimately binding and storing the collapse data with the product identity information. This is ultimately integrated into a high-efficiency, high-precision, low-cost dedicated solution that enables full inspection and data traceability, effectively overcoming the limitations of existing inspection methods in terms of efficiency, accuracy, cost, and coverage, and meeting the stringent requirements for 100% online control of key dimensions in the large-scale automated production of power batteries.

[0036] The present invention comprises a precision detection system in which the contour positioning block 4, the cylinder clamping mechanism 5, and the pneumatic displacement sensor 3 work in concert. A magnet 11 mounted on one end of the contact element 9 is stably attracted to a steel block 10 fixed on the sensor mounting base 7. This design provides the contact element 9 with a uniform and gapless preload, ensuring the constancy of the force state. During detection, the sag of the battery pack cover acts on the other end of the contact element 9, driving it to transmit displacement to the pneumatic unit 8. This unit employs a piston structure, where a fixed ceramic ball at its tip interacts with the flat contact surface of the contact element 9, linearly converting minute displacements into air pressure changes, which are then captured by the built-in air pressure detection element. Finally, the industrial control unit 12 runs various embedded control programs (such as signal linearization calibration and tolerance judgment algorithms), simultaneously processing the air pressure signal and the product information collected by the barcode scanning unit 13, thereby outputting accurate and traceable sag detection results. This achieves a high-precision fusion of magnetic stability and contact-type pneumatic-electric conversion principle in automated detection.

[0037] Example 2:

[0038] In this embodiment, a detection platform 2 is fixedly mounted on the frame 1. The detection platform 2 is fixedly mounted with a pneumatic displacement sensor 3, a contour positioning block 4, a clamping mechanism 5, and an operating unit 6. The pneumatic displacement sensor 3 includes a mounting base 7, a pneumatic unit 8, and a contact element 9. A steel block 10 is fixedly mounted on the mounting base 7, and a magnet 11 is fixedly mounted on the contact element 9. The magnet 11 attracts and fixes the steel block 10. The clamping mechanism 5 is located beside the contour positioning block 4. The operating unit 6 includes an industrial control unit 12 and a barcode scanning unit 13.

[0039] During the testing process, the operator places the top cover of the new energy vehicle battery pack to be tested onto the contour positioning block 4 of the testing platform 2. The contour positioning block 4 matches the contour shape of the top cover, achieving rapid and accurate positioning. Subsequently, the clamping mechanism 5 is activated, firmly clamping the top cover onto the testing platform 2, eliminating measurement errors caused by workpiece vibration or displacement during the testing process, and ensuring the stability and repeatability of the testing process. The contact element 9 of the pneumatic displacement sensor 3 is attracted and fixed to the steel block 10 on the fixing base 7 by the magnet 11. This magnetic attraction design provides the contact element 9 with a uniform and gapless preload, ensuring the constantness of the force state and avoiding measurement deviations introduced by mechanical clearances.

[0040] The piston structure of the pneumatic displacement sensor 3 extends, lifting the contact element 9 so that it directly contacts the area to be measured on the battery pack cover. When the cover experiences a collapse deformation, the contact element 9 converts the microscopic collapse amount into a displacement change. The pneumatic unit 8 captures this displacement and converts it into a change in air pressure signal. The embedded signal processing algorithm calculates the precise collapse amount. The industrial control unit 12 runs various control programs, including signal linearization calibration and tolerance judgment algorithms, and simultaneously processes the air pressure signal output by the pneumatic displacement sensor 3 and the product identification information collected by the barcode scanning unit 13, realizing the automatic binding and storage of collapse amount data and product identification information.

[0041] During the inspection process, the barcode scanning unit 13 automatically scans the identification mark on the battery pack cover and transmits the product information to the industrial control unit 12 in real time, ensuring the traceability of inspection data for each product. The entire inspection process is centrally controlled by the operation unit 6, achieving automated operation without manual intervention, thus improving inspection efficiency and consistency. Through the synergistic effects of contour positioning, clamping stabilization, magnetic contact, and pneumatic-electric conversion, this equipment achieves high-precision online detection of the battery pack cover collapse, meeting the needs of full inspection coverage of critical dimensions in large-scale production.

[0042] The equipment described in this embodiment is suitable for production line integration of battery pack covers for new energy vehicles. It can quickly respond to high-cycle testing demands while maintaining reliable measurement accuracy. Through the non-mechanical pre-tightening design of the pneumatic displacement sensor 3 and the intelligent control of the operating unit 6, it effectively overcomes the limitations of traditional testing methods in terms of efficiency, accuracy, and cost, providing a dedicated solution for quality control of battery pack covers. The optimized structural layout of the equipment streamlines the testing process, automating the entire process from positioning to data output, ensuring the objectivity and repeatability of the test results, and contributing to the improvement of the safety and reliability of power battery systems.

[0043] Example 3:

[0044] In this embodiment, the pneumatic displacement sensors 3 are arranged in a rectangular array on the detection platform 2. These sensors are concentrated in the central area of ​​the detection platform 2, forming a rectangular detection area with dimensions of 800mm*1230mm. This rectangular area corresponds to the abdominal area of ​​the battery pack cover structure, which is most prone to deformation problems. Through this high-density targeted arrangement, comprehensive coverage detection of key deformation areas can be achieved.

[0045] In the specific implementation process, when the battery pack cover to be tested is placed on the testing platform 2, it is first precisely positioned by the contour positioning block 4 to ensure that the relative position of the cover and the testing platform 2 fully meets the testing requirements. Then, the clamping mechanism 5 is activated to firmly fix the battery pack cover on the testing platform 2, effectively avoiding measurement errors caused by workpiece displacement or vibration during the testing process. At this time, the pneumatic displacement sensors 3, which are arranged in a rectangular array, start to work. The contact parts 9 of each sensor maintain a stable contact state under the magnetic attraction. Through the attraction between the magnet 11 and the steel block 10 on the fixing base 7, a uniform pre-tightening force is provided to the contact parts 9 to ensure the consistency of the force state during the measurement process.

[0046] Upon issuance of the detection command, the piston structure of the pneumatic displacement sensor 3 extends synchronously, pushing the contact element 9 to establish stable contact with the surface of the battery pack cover. Because the sensors are densely arranged in a rectangular array in the key deformation area, deformation data from multiple measurement points can be collected simultaneously. Each sensor converts the microscopic collapse deformation of the battery pack cover surface into a corresponding change in air pressure signal based on the change in piston extension. These air pressure signals are collected in real time by the pneumatic unit 8 and transmitted to the industrial control unit 12 for processing.

[0047] The industrial control unit 12 runs its built-in calibration algorithm and tolerance judgment program to synchronously analyze the received multi-channel air pressure signals and calculate the precise collapse value for each measurement point. Simultaneously, the barcode scanning unit 13 automatically collects product identification information, and the industrial control unit 12 binds and stores the collapse detection data with the product information to form a complete detection record. This rectangular array arrangement is specifically optimized for the abdominal area of ​​the battery pack cover, significantly improving the detection accuracy of key areas by increasing the density of measurement points, and accurately capturing subtle deformation characteristics in this region.

[0048] The entire inspection process is fully automated, requiring no manual intervention from workpiece positioning and clamping to data acquisition and processing. A rectangular array of pneumatic displacement sensors works collaboratively to form a high-precision detection network for critical deformation areas of the battery pack cover, ensuring the reliability and repeatability of measurement results. This arrangement not only improves inspection efficiency but, more importantly, through targeted optimization of sensor distribution, enables focused monitoring of the most deformable areas of the battery pack cover, providing accurate data support for product quality control. Upon completion of inspection, the system automatically generates an inspection report containing product identification information and collapse data, providing complete evidence for quality traceability throughout the production process.

[0049] Example 4:

[0050] In one embodiment of a high-precision automatic detection device for the underside measurement of a new energy vehicle battery pack cover, the frame 1 serves as the overall support structure, with a movable frame 14 fixedly installed at its bottom. This frame is made of rigid material to ensure stability and prevent deformation during movement. Rollers 15 are fixedly installed at the four corners of the movable frame 14. The rollers 15 are made of wear-resistant material and equipped with locking devices, allowing the device to be easily pushed to a designated workstation on the production line and accurately positioned and fixed through the locking mechanism. This movable design enables the detection device to be quickly adjusted in deployment according to different production line layouts or product model changes, without the need for reinstallation or infrastructure modification. This significantly shortens equipment changeover and production line adaptation time, effectively improving production flexibility and equipment utilization.

[0051] During the testing process, the operator places the top cover of the battery pack to be tested on the contour positioning block 4 of the testing platform 2. The contour positioning block 4 precisely matches the contour of the top cover, achieving rapid self-centering positioning. Subsequently, the clamping mechanism 5 extends from the side and presses the top cover firmly onto the surface of the testing platform 2 with constant pressure, eliminating minor displacement or vibration interference of the workpiece during the measurement process. The fixing seat 7 of the pneumatic displacement sensor 3 generates an adsorption force between the steel block 10 and the magnet 11 at the bottom of the contact member 9, keeping the contact member 9 in a pre-tightened state. When the sensor is activated, its internal piston pushes the contact member 9 upward to directly contact the area to be tested on the top cover of the battery pack, converting the downward deformation of the top cover surface into piston displacement. This displacement signal is then converted into air pressure change by the pneumatic unit 8 and transmitted to the industrial control unit 12.

[0052] The industrial control unit 12 incorporates a signal processing algorithm to linearize and calibrate the received air pressure data, accurately calculating the collapse amount of the battery pack cover. Simultaneously, the barcode scanning unit 13 automatically scans the product identification, binding the test results with product identity information and storing it in the database for full data traceability. The entire testing process is completed automatically under the control of the operation unit 6, requiring no manual intervention. This ensures consistent measurement accuracy and enables efficient continuous operation. Through the cooperation of the movable frame 14 and rollers 15, the equipment can be quickly transferred and deployed between different production lines, adapting to the flexible production needs of multi-variety, small-batch production, providing a high-precision, high-efficiency automated testing solution for the quality control of new energy vehicle battery packs.

[0053] Example 5:

[0054] In this embodiment, the detection platform 2 is fixedly equipped with a lifting assembly 16, which includes a first cylinder 17 and a support plate 18. The drive end of the first cylinder 17 is fixedly connected to the support plate 18. The lifting assembly 16 is distributed in the detection area of ​​the pneumatic displacement sensor 3. Before the detection process begins, the first cylinder 17 drives the support plate 18 to move upward, smoothly lifting the battery pack cover to a horizontal position, ensuring that the surface of the cover is consistent with the detection reference plane, thereby providing accurate initial conditions for subsequent measurements. This leveling operation eliminates the initial deformation caused by the workpiece's own weight or improper placement, allowing the pneumatic displacement sensor 3 to directly and accurately detect the actual collapse of the cover, avoiding the introduction of measurement errors.

[0055] During the testing process, the lifting assembly 16 works efficiently in conjunction with other components. After the battery pack cover is quickly positioned by the contour positioning block 4, the clamping mechanism 5 firmly clamps it to prevent displacement or vibration during testing. At this time, the first cylinder 17 of the lifting assembly 16 drives the support plate 18 to retract, making room for the contact 9 of the pneumatic displacement sensor 3, ensuring that the contact 9 can extend unobstructed and directly contact the area to be tested on the cover. The pneumatic displacement sensor 3 converts the microscopic collapse deformation into a change in air pressure signal through the magnetically fixed contact 9. The pneumatic unit 8 accurately calculates the collapse value, and the industrial control unit 12 synchronously processes the data and binds it with the product information collected by the barcode scanning unit 13 for storage, achieving full inspection coverage and data traceability.

[0056] After inspection, the lifting assembly 16 plays a crucial role once again. The first cylinder 17 drives the support plate 18 upward, restoring the battery pack cover to a horizontal position. This operation effectively prevents the cover from collapsing and deforming due to long-term stress or material properties during static placement, ensuring that the workpiece maintains the designed flatness during subsequent processes or storage. The cyclical leveling function of the lifting assembly 16 not only improves inspection accuracy but also extends the service life of the battery pack cover. Automation reduces human intervention, adapting to the high-speed requirements of large-scale production lines.

[0057] The working principle of the lifting assembly 16 is based on the organic combination of pneumatic drive and mechanical support. The first cylinder 17 serves as the power source, precisely controlling the extension and retraction of the drive end to drive the support plate 18 to achieve smooth vertical lifting and lowering. The support plate 18 is made of rigid material, and its surface design ensures uniform distribution when in contact with the battery pack cover, avoiding localized stress concentration. During the pre-testing leveling stage, the support plate 18 rises to a predetermined height, supporting the overall weight of the cover and correcting its planar state. During testing, the support plate 18 promptly exits the testing area to ensure unobstructed sensor operation. After testing, the support plate 18 rises again to level the cover, forming a complete protection cycle. This design achieves dual optimization of testing efficiency and workpiece protection through timing control and positional accuracy management.

[0058] Throughout this embodiment, the lifting component 16, as a crucial element of the testing equipment, not only assists in measurement but also enhances quality control through automated leveling operations. The lifting component 16, in conjunction with the pneumatic displacement sensor 3, the contour positioning block 4, the clamping mechanism 5, and the operating unit 6, forms a closed-loop testing system. This system, uniformly scheduled by the industrial control unit 12, ensures seamless integration of the lifting action and the testing process, guaranteeing the reliability of measurement data and effectively preventing the accumulation of deformation on the battery pack cover, thus providing a solid guarantee for the safety and reliability of new energy vehicle power batteries.

[0059] Example 6:

[0060] In this embodiment, the clamping mechanism 5 is located beside the contour positioning block 4 of the detection platform 2, and consists of a second cylinder 19 and a pressure block 20 as the core driving component. The driving end of the second cylinder 19 is rigidly connected to the pressure block 20 to ensure that no offset or loosening occurs during pressure transmission. An adjustable pressure rod 21 is fixedly installed on the pressure block 20. The end of the pressure rod is designed to have a contact surface that matches the shape of the battery pack cover. Its extension length can be changed by mechanical adjustment methods such as screwing in or pin positioning, thereby adapting to battery pack covers of different thicknesses.

[0061] When the testing process begins, the operating unit 6 controls the second cylinder 19 to push the pressure block 20 downwards, causing the adjustable pressure rod 21 to press firmly against the surface of the battery pack cover with constant pressure. At this time, the clamping force generated by the pressure rod and the contour positioning block 4 form a mechanical balance, effectively suppressing the vibration or displacement of the workpiece during the testing process. The length adjustment mechanism of the adjustable pressure rod 21 adopts a stepped positioning structure, allowing the operator to quickly select the corresponding step according to the thickness specification of the cover, ensuring that the clamping force is always perpendicular to the plane being measured, and avoiding measurement errors caused by angular deviations.

[0062] Under continuous compression, the contact element 9 of the pneumatic displacement sensor 3 maintains stable contact under magnetic attraction, converting the collapse of the upper cover into a pneumatic pressure signal. The compression mechanism 5 ensures a stable measurement reference surface between the contact element 9 and the surface of the upper cover by maintaining a constant contact pressure. The mechanism is also equipped with a pressure buffer device, which absorbs some of the impact energy when the adjustable pressure rod 21 contacts the upper cover, preventing damage to the precision measurement surface. The entire compression process is synchronized with the detection process. After the pneumatic displacement sensor 3 completes data acquisition, the operation unit 6 commands the second cylinder 19 to retract the pressure block 20, releasing the constraint on the workpiece.

[0063] The clamping mechanism 5 is characterized by its adaptive clamping of workpieces of varying thicknesses via an adjustable pressure rod 21, covering the thickness tolerance range of common battery pack covers. The second cylinder 19 employs a dual-action control mode, enabling both rapid downward pressure and precise control of the return speed, effectively improving the inspection cycle. An anti-rotation structure is incorporated at the connection between the pressure block 20 and the adjustable pressure rod 21, ensuring a stable pressure direction even after multiple adjustments. This modular design allows the clamping mechanism 5 to meet the high-precision inspection requirements for workpiece stability while also possessing excellent process adaptability, facilitating rapid switching between different product specifications on the production line.

[0064] During long-term operation, the mechanical components of the clamping mechanism 5 are made of wear-resistant materials, and the threaded part of the adjustable pressure rod 21 is equipped with an anti-loosening device to ensure that the preset length can be maintained even under continuous vibration. The second cylinder 19 is equipped with a soft landing buffer at the end of its stroke to avoid impact load on the workpiece. This mechanism forms an organic whole with other components of the detection platform 2, and through coordinated actions, it realizes a fully automated process of workpiece positioning, clamping, detection, and release, providing a reliable clamping guarantee for high-precision detection of the battery pack cover collapse.

[0065] Example 7:

[0066] In this embodiment, the testing platform 2 is fixedly equipped with a convenient control panel 22, which integrates multiple buttons 23 to simplify equipment operation. The convenient control panel 22 is connected to the industrial control unit 12 via internal circuitry, enabling rapid transmission and execution of commands. During equipment startup, the operator presses the start button 23 on the convenient control panel 22 to trigger the initialization program of the industrial control unit 12, automatically activating the pneumatic displacement sensor 3, the clamping mechanism 5, and the barcode scanning unit 13, thus entering the testing state. This design avoids the complex multi-step operations of traditional equipment, significantly improving testing efficiency, and is particularly suitable for high-frequency applications on production lines.

[0067] In the event of any abnormality during the inspection process, such as workpiece positioning deviation or sensor signal anomaly, the operator can immediately press the emergency stop button 23 on the convenient control panel 22. This button 23 directly cuts off the main power supply to the equipment via hardwired connection, ensuring that the clamping mechanism 5 quickly releases the workpiece, and the pneumatic displacement sensor 3 automatically resets, preventing workpiece damage or measurement data distortion caused by continuous equipment operation. The layout of the convenient control panel 22 has been optimized, and the button 23 features a large size and clear labeling, facilitating quick identification and operation by operators in demanding production environments, effectively reducing the risk of human error.

[0068] The convenient control panel 22 also integrates status indication functions, displaying the equipment's operating mode in real time via built-in indicator lights, such as standby, testing, or fault status. After the equipment completes one testing cycle, the industrial control unit 12 binds and stores the collapse data with the product information collected by the barcode scanning unit 13, and provides feedback on the testing results via the confirmation button 23 on the convenient control panel 22. Operators can determine whether to repeat the test or adjust the equipment parameters based on the indicator light status and button 23 feedback, thereby achieving refined control of the testing process.

[0069] Furthermore, the convenient control panel 22 is designed with ergonomic principles in mind. Its installation position is coordinated with the operating unit 6, ensuring easy access for operators whether standing or moving. The panel material is dustproof and splashproof, adapting to various working conditions in industrial environments. Through this integrated control method, the equipment maintains high-precision testing performance while significantly improving operational convenience and safety, providing a reliable guarantee for large-scale full inspection of new energy vehicle battery packs.

[0070] Example 8:

[0071] In this embodiment, a cabinet 24 is fixedly mounted on the frame 1, and lifting lugs 25 are fixedly installed at the four corners of the testing platform 2. The cabinet 24 is used to centrally install various industrial control equipment. It adopts an embedded structure and is installed inside the frame 1, making the overall layout compact and reasonable. The lifting lugs 25 distributed at the four corners of the testing platform 2 can be used to lift and move the entire equipment, which facilitates rapid changeover and flexible deployment on the production line to meet the needs of different production cycles and site conditions.

[0072] During the testing process, the top cover of the battery pack under test is first positioned quickly and accurately by the contour positioning block 4, ensuring that the workpiece is completely in contact with the testing reference surface. Then, the clamping mechanism 5 actuates, firmly clamping the workpiece onto the testing platform 2, avoiding measurement errors caused by vibration or displacement during the testing process. The pneumatic displacement sensor 3, as the core measuring component, has its mounting base 7 magnetically connected to the magnet 11 at the end of the contact element 9 via a steel block 10. This structure provides a uniform preload to the contact element 9, ensuring a stable and reliable contact state. When the sensor piston structure extends, the top of the contact element 9 directly contacts the area under test of the battery pack top cover, converting the microscopic deformation into a change in air pressure signal. The pneumatic unit 8 collects and calculates the collapse value in real time.

[0073] The industrial control unit 12 in operation unit 6 runs a dedicated control program to perform linearization calibration and tolerance judgment on the acquired signals, while the barcode scanning unit 13 automatically reads the product identification information. Finally, the collapse measurement data is bound and stored with the product information to form a complete quality traceability record. The entire inspection process is completed under automated control, achieving a high-efficiency, high-precision online full inspection function.

[0074] This embodiment optimizes the equipment structure through embedded installation in the cabinet 24, and improves equipment mobility and deployment flexibility through the design of the lifting lugs 25. Combined with a precision positioning, clamping, and measurement system, it effectively solves the problems of low efficiency and poor accuracy of traditional testing methods, and meets the stringent requirements for full inspection control of key dimensions in the large-scale production of new energy vehicle battery packs.

[0075] Example 9:

[0076] This embodiment provides a high-precision automatic detection method for the under-cab of a battery pack cover in a new energy vehicle. Specifically, it includes the following steps: First, the operator adjusts the position and height of the contour positioning block 4 according to the actual dimensions of the battery pack cover to be tested, ensuring that the contour positioning block 4 perfectly matches the outline of the cover, achieving precise positioning. This step, through the physical coupling between the contour positioning block 4 and the cover, provides a stable benchmark for subsequent testing, avoiding measurement deviations caused by inaccurate positioning, thereby ensuring the repeatability and consistency of the testing process.

[0077] Next, the top cover of the battery pack to be tested is placed smoothly on the testing platform 2, ensuring it is tightly coupled and fixed with the pre-adjusted contour positioning block 4. The design of the testing platform 2 ensures that the top cover will not slide or shift during placement, further enhancing the reliability of positioning. This step, through the cooperation of the mechanical structure, enables rapid clamping of the workpiece, laying the foundation for subsequent pressing and testing operations, effectively improving overall testing efficiency, and is suitable for the high-speed cycle requirements of production lines.

[0078] Then, the scanning unit 13 is activated to automatically scan the QR code or barcode attached to the surface of the battery pack cover, quickly obtaining the product's unique identification information. The scanning unit 13 accurately reads the encoded data using optical recognition technology and transmits the information to the industrial control unit 12 for processing in real time. This step achieves automated collection of product information, ensuring the traceability of inspection data for each cover, providing a reliable basis for quality control and data analysis, and avoiding errors and delays that may result from manual input.

[0079] Finally, the clamping mechanism 5 is activated, working in conjunction with the contour positioning block 4 to firmly clamp and fix the battery pack cover. Simultaneously, the contact element 9 of the pneumatic displacement sensor 3 directly contacts the surface of the cover. When the collapsing area of ​​the cover acts on the contact element 9, the contact element 9 transmits the collapsing deformation to the pneumatic unit 8. The pneumatic unit 8 accurately calculates the collapsing amount based on the change in air pressure signal. This collapsing amount is automatically bound to the previously acquired identification information and stored in the data system. This step utilizes the contact measurement principle of the pneumatic displacement sensor 3 to convert microscopic deformation into a quantifiable air pressure signal. Combined with the built-in algorithm of the industrial control unit 12 for linearization calibration and tolerance judgment, it ensures high accuracy and reliability of the detection results, achieving full inspection coverage and data traceability, meeting the quality control requirements in the large-scale production of new energy vehicle battery packs.

[0080] Example 10:

[0081] This embodiment is based on a dedicated testing device comprising a frame 1, a testing platform 2, a pneumatic displacement sensor 3, a contour positioning block 4, a clamping mechanism 5, and an operating unit 6. The pneumatic displacement sensor 3 consists of a fixed base 7, a pneumatic unit 8, and a contact element 9. The fixed base 7 is equipped with a steel block 10, and the contact element 9 is equipped with a magnet 11, achieving a stable connection through magnetic attraction. The clamping mechanism 5 is arranged adjacent to the contour positioning block 4, and the operating unit 6 integrates an industrial control unit 12 and a barcode scanning unit 13. The core of this method lies in triggering a fully automated testing process through barcode scanning. The specific implementation process is as follows:

[0082] First, the operator places the battery pack cover to be tested onto the contour positioning block 4 of the testing platform 2. The contour positioning block 4 matches the contour shape of the cover, achieving rapid initial positioning through physical coupling. Subsequently, the scanning unit 13 is activated to scan and identify the QR code or barcode attached to the surface of the cover. Once the scanning unit 13 successfully reads the encoded information, the system automatically triggers subsequent testing steps without manual intervention, thus achieving complete automation of the testing process.

[0083] After successful barcode scanning, the clamping mechanism 5 immediately activates, firmly pressing the battery pack cover onto the contour positioning block 4. This step effectively eliminates any vibration or displacement that may occur during the inspection process, providing a stable foundation for high-precision measurement. Next, the pneumatic displacement sensor 3 begins operation, its piston structure extending outwards to push the contact element 9 upwards until the measuring end of the contact element 9 makes tight contact with the surface of the area to be measured on the battery pack cover. Since the contact element 9 is magnetically attached to the steel block 10 on the fixing base 7 via the magnet 11, this magnetic connection provides a uniform and gapless preload to the contact element 9, ensuring the consistency of the force state during measurement and avoiding measurement deviations caused by loose connections.

[0084] When contact element 9 contacts the surface of the top cover, pneumatic unit 8 converts the collapse deformation of the central area of ​​the battery pack top cover into a corresponding air pressure signal based on the change in the extension of the piston structure. This air pressure signal is acquired in real time and transmitted to industrial control unit 12. Industrial control unit 12 runs an embedded signal processing program, including signal linearization calibration and tolerance judgment algorithms, to accurately analyze the received air pressure data and calculate the actual collapse amount. Simultaneously, industrial control unit 12 automatically binds the calculated collapse data with the product identification information previously collected by barcode scanning unit 13, forming a complete data record, which is then stored in the system database. This data association mechanism enables traceability of the test results, providing a reliable basis for quality analysis and production management.

[0085] The entire inspection process is automatically and continuously executed upon successful barcode scanning. From workpiece positioning, clamping and fixing, sensor contact to data calculation and storage, each step is seamlessly connected, significantly improving inspection efficiency and consistency. This method achieves high-precision measurement of slump by combining contour positioning, magnetic stable contact, and the principle of gas-electric conversion. Simultaneously, the automatic barcode scanning triggering mechanism effectively overcomes the shortcomings of low efficiency and error-prone manual operation in traditional inspection methods, meeting the needs of full inspection coverage and real-time quality monitoring in the large-scale automated production of new energy vehicle battery packs.

[0086] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0087] The above description is only used to illustrate the technical solution of the present invention and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention, as long as they do not depart from the spirit and scope of the technical solution of the present invention, should be covered within the scope of the claims of the present invention.

Claims

1. A high-precision automatic detection equipment for the amount of a new energy automobile battery pack upper cover, comprising a rack, the detection platform is fixedly installed on the rack, characterized in that, The detection platform is fixedly installed with a pneumatic displacement sensor, a profiling positioning block, a pressing mechanism and an operation unit.

2. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover down according to claim 1, characterized in that, The pneumatic displacement sensor is arranged in a rectangular array.

3. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, The movable frame is fixedly installed at the bottom of the rack.

4. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, The detection platform is fixedly installed with a lifting assembly, which comprises a first cylinder and a supporting plate.

5. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, The pressing mechanism comprises a second cylinder and a pressing block.

6. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, The detection platform is fixedly installed with a convenient control panel, which is fixedly installed with a plurality of keys.

7. The high-precision automatic detection equipment for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, The rack is fixedly installed with a cabinet, and the detection platform is fixedly installed with lifting lugs at four corners.

8. A high-precision automatic detection method for the amount of a new energy vehicle battery pack upper cover, comprising the detection device of claims 1-7, characterized in that, The method comprises the following steps: S1: adjusting the position and height of the profiling positioning block to match the shape of the battery pack upper cover to be detected; S2: placing the battery pack upper cover to be detected on the detection platform and coupling and fixing it with the profiling positioning block; S3: the code scanning unit scans the two-dimensional code or bar code on the battery pack upper cover to be detected to obtain the identity information of the product; S4: starting the pressing mechanism, cooperating with the profiling positioning block to clamp and fix the battery pack upper cover to be detected, the contact piece of the pneumatic displacement sensor being in contact with the surface of the battery pack upper cover to be detected, the contact piece transmitting the landing effect to the pneumatic unit, detecting the landing amount of the battery pack upper cover to be detected, and binding and storing the landing amount with the identity information.

9. The high-precision automatic detection method for the amount of the new energy vehicle battery pack upper cover according to claim 1, characterized in that, After the code scanning unit successfully scans the two-dimensional code or bar code, the S4 is automatically executed.

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