Battery pack airtight helium detection system and method

Abstract

The invention provides a battery pack airtight helium detection system and method, and belongs to the technical field of battery pack quality detection. The system comprises a helium mixing work station; a helium detection station; a Pack trolley; the cover box helium detection tool is arranged at the top end of the Pack trolley; the upper computer is respectively connected with the helium mixing work station, the helium detection work station and the Pack trolley; the helium mixing work station comprises a helium mixing frame; the at least one helium mixing cabinet is arranged at the top end of the helium mixing frame and is connected with the upper computer; the helium cylinders are arranged on the side edge of the helium mixing frame; and the input end of the helium filling pipeline is communicated with the output end of the helium mixing cabinet. The battery pack air tightness detection device has the advantages that the reliability of battery pack air tightness detection is greatly improved, and the omission ratio is greatly reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of battery pack quality inspection, and particularly discloses a battery pack air-tight helium detection system and method. BACKGROUND

[0002] With the deepening of the new energy technology revolution and the acceleration of industrialization, electric vehicles with battery packs as the core power source have entered a rapid development stage. As one of the important technical routes of current power battery systems, CTP (Cell to Pack) battery packs have shown broad market application prospects due to their high energy density, superior endurance performance, and lower overall use cost. However, in the process of large-scale manufacturing, battery packs still have obvious shortcomings in production efficiency, consistency quality control, and safety and reliability management, especially in the aspect of air-tightness guarantee, which restricts the improvement of the overall quality of products.

[0003] As a key quality control node in the production process of battery packs, air-tightness detection is directly related to the sealing performance and long-term operation safety of products. The traditional air-tightness detection method widely used in the industry mainly has the following technical defects: first, the existing method is difficult to realize accurate positioning of the leakage point, which leads to the lack of pertinence of subsequent repair work, not only greatly increasing the maintenance workload, but also possibly causing secondary leakage due to the failure to completely eliminate the leakage source, which seriously affects production efficiency and product yield; second, due to the limitation of detection accuracy and stability, there is a certain proportion of misjudgment and missed detection in the traditional method, which causes some battery packs with substandard sealing performance to flow into the market, and then may cause circuit failure, operation interruption or even safety accidents due to water vapor intrusion during vehicle operation, which not only affects user experience, but also significantly increases after-sales maintenance cost and brand risk.

[0004] Therefore, how to provide a battery pack air-tight helium detection system and method to improve the reliability of battery pack air-tightness detection and reduce the missed detection rate has become a technical problem to be solved. SUMMARY

[0005] The technical problem to be solved by the present application is to provide a battery pack air-tight helium detection system and method to improve the reliability of battery pack air-tightness detection and reduce the missed detection rate.

[0006] In a first aspect, the present application provides a battery pack air-tight helium detection system, comprising: a helium mixing station; a helium detection station; a Pack trolley; a cover box helium detection tool arranged at the top end of the Pack trolley; an upper computer connected with the helium mixing station, the helium detection station, and the Pack trolley, respectively; The helium mixing station comprises: a helium mixing frame; at least one helium mixing cabinet arranged at the top end of the helium mixing frame and connected with the upper computer; a plurality of helium cylinders arranged at the side of the helium mixing frame; at least one helium filling pipeline, the input end of which is communicated with the output end of the helium mixing cabinet; The helium detection station comprises: an equipment outer frame provided with a roller shutter door; a control panel arranged at the side of the equipment outer frame and connected with the upper computer; at least one helium exhaust module arranged at the top end of the equipment outer frame, communicated with the inside of the equipment outer frame and connected with the control panel; a jacking mechanism arranged in the inside of the equipment outer frame and connected with the control panel; a helium detector arranged in the inside of the equipment outer frame and connected with the control panel; a robot arranged in the inside of the equipment outer frame through a walking shaft and connected with the control panel; a calibration assembly arranged in the inside of the equipment outer frame and connected with the control panel; a suction gun assembly arranged at the end of the mechanical arm of the robot and connected with the control panel.

[0007] Further, the calibration assembly comprises: a mounting plate arranged in the inside of the equipment outer frame, provided with at least one active leak hole and one passive leak hole; a suction gun position detection sensor arranged on the mounting plate and connected with the control panel; at least one calibration cover box arranged on the mounting plate; a laser ranging calibration block arranged on the mounting plate; a camera calibration plate arranged on the mounting plate; a robot calibration piece arranged on the mounting plate.

[0008] Further, the suction gun assembly comprises: a mounting bracket arranged at the end of the mechanical arm of the robot; a camera arranged on the mounting bracket and connected with the control panel; a helium cleaning gun arranged on the mounting bracket and connected with the control panel; a helium detection gun arranged on the mounting bracket and connected with the helium detector; A laser range finder is arranged on the mounting frame and connected with the control panel. A collision alarm assembly is arranged on the mounting frame and connected with the control panel.

[0009] In a second aspect, the application provides a battery pack airtight helium detection method, comprising the following steps: Step S1, place the battery pack in the cover box helium detection tool, and move the cover box helium detection tool to the helium mixing station through the Pack trolley; Step S2, connect the gas outlet of the cover box helium detection tool with the connector of the battery pack, connect the inflation port with the helium filling pipeline, and sequentially fill helium into the battery pack through the helium mixing cabinet, the helium filling pipeline and the cover box helium detection tool, then remove the helium filling pipeline, and the inflation port of the cover box helium detection tool is automatically sealed; Step S3, open the roller shutter door of the helium detection station, move the cover box helium detection tool to the jacking mechanism of the helium detection station through the Pack trolley, position and jack through the jacking mechanism, and then close the roller shutter door; Step S4, the robot moves the suction gun assembly to the calibration assembly to perform calibration operation, after calibration is completed, the suction gun assembly is moved around the battery pack at a preset speed through the linkage of the walking shaft and the mechanical arm, and the battery pack is detected for airtightness by the helium detector. The application has the following advantages: 1. By adopting the high-sensitivity helium mass spectrometry leak detection method, and combining with the robot carrying the suction gun assembly to automatically scan the battery pack along the preset path, the precise capture and positioning of the tiny leakage points are realized; at the same time, by integrating the calibration assembly for real-time calibration before detection, and utilizing the laser range finder to dynamically control the optimal distance between the suction gun and the detection surface, and by using the closed detection environment to isolate external interference, the stability of the detection process and the repeatability of the results are systematically improved, the risk of misjudgment and missed detection is significantly reduced, the reliability of the battery pack airtight detection is greatly improved, and the missed detection rate is greatly reduced.

[0010] 2. By using the upper computer to uniformly control the helium mixing station, the helium detection station and the Pack trolley, the centralized management and automatic operation of the whole detection process are realized; such integrated design reduces manual intervention, improves detection efficiency, and reduces the risk of operation error; the cooperative work between the stations ensures the seamless connection of the battery pack from helium filling to detection, and is especially suitable for large-scale production lines, and improves the overall production rhythm and consistency.

[0011] 3、The helium detection station is equipped with calibration components and suction gun components, including active leak holes, passive leak holes, cameras, laser range finders, etc., which can automatically calibrate before detection to ensure the accuracy and repeatability of the helium detector; the robot can accurately move the suction gun components at a preset speed under the drive of the walking shaft and mechanical arm, avoiding human operation deviation, thereby realizing high-precision detection of the battery pack airtightness and meeting strict quality standards.

[0012] 4、Helium is used as the detection medium, which is an inert gas and harmless, avoiding the safety risks that may be caused by traditional detection methods; at the same time, the helium detection station is provided with a helium exhaust module to timely process and recycle residual helium, reducing the influence of gas leakage on the environment; the automatic sealing design of the cover box helium detection tool further prevents helium from escaping, meeting the environmental protection requirements of modern manufacturing.

[0013] 5、Through the robot and the movable Pack trolley, the detection requirements of battery packs of different sizes and shapes can be met; the various sensors and calibration components in the calibration component (such as laser ranging calibration blocks and camera calibration boards) allow the system to quickly adjust parameters to adapt to different production conditions, and this modular design makes the system easy to expand or modify, facilitating future technology upgrading or production line adjustment.

[0014] 6、The control panel and the upper computer provide an intuitive user interface, and the operator can easily monitor the detection status and parameters and adjust the process in real time; the design of the roller shutter door and the jacking mechanism simplifies the loading and unloading operation of the battery pack, reducing physical labor; the impact alarm component and other safety features further reduce the risk of equipment damage, improving user experience and maintenance convenience.

[0015] 7、The automatic process significantly reduces the labor demand and detection time, thereby reducing the long-term operating cost; the helium mixing station centrally manages the helium supply, avoiding gas waste; the robot of the helium detection station has a fast detection speed and high consistency, reducing repetitive work and waste rate.

[0016] 8、The calibration component integrates various tools such as active leak holes, passive leak holes, and suction gun position detection sensors, allowing comprehensive self-calibration before detection to ensure data accuracy; this design solves the problem of complicated calibration in traditional helium detection, improving the reliability and efficiency of detection.

[0017] 9. The helium mixing station, helium detection station and Pack trolley are controlled by the host computer, realizing the full-process automation and high integration of helium filling, transplanting, positioning and detection, significantly improving the detection efficiency and consistency; the system ensures the high precision and reliability of the air tightness detection by driving the suction gun assembly with the robot and combining with the precise calibration mechanism (such as laser ranging, active / passive leak hole calibration), while using helium as a safety medium and being equipped with helium exhaust and automatic sealing design, taking into account environmental protection and operation safety, the overall scheme improves the detection quality and automation level while having good adaptability and cost effectiveness. BRIEF DESCRIPTION OF DRAWINGS

[0018] The application will be further described below with reference to the accompanying drawings and embodiments.

[0019] Figure 1 is a structural schematic diagram of the helium mixing station of the application.

[0020] Figure 2 is a structural schematic diagram of the helium detection station of the application.

[0021] Figure 3 is a structural schematic diagram of the helium detection station of the application.

[0022] Figure 4 is a structural schematic diagram of the calibration assembly of the application.

[0023] Figure 5 is a structural schematic diagram of the suction gun assembly of the application.

[0024] Figure 6 is a flowchart of a battery pack air tightness helium detection method of the application.

[0025] MARK DESCRIPTION: 1-helium mixing station, 2-helium detection station, 3-Pack trolley, 4-shield box helium detection tooling, 5-battery pack, 11-helium mixing frame, 12-helium mixing cabinet, 13-helium cylinder, 14-helium filling pipeline, 21-equipment outer frame, 22-control panel, 23-helium exhaust module, 24-jack-up mechanism, 25-helium detector, 26-robot, 27-calibration assembly, 28-suction gun assembly, 211-roller shutter door, 261-traveling shaft, 271-mounting plate, 272-suction gun position detection sensor, 273-shield box, 274-laser ranging calibration block, 275-camera calibration plate, 276-robot calibration piece, 2711-active leak hole, 2712-passive leak hole, 281-mounting bracket, 282-camera, 283-helium exhaust gun, 284-helium detection gun, 285-laser range finder, 286-impact alarm assembly. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application have the following general idea: by adopting a high-sensitivity helium mass spectrometry leak detection method, and in combination with the robot 26 carrying the suction gun assembly 28 to automatically scan the battery pack 5 along a preset path, precise capture and positioning of a tiny leakage point are achieved; meanwhile, by integrating the calibration assembly 27 to perform real-time calibration before detection, and by using the laser range finder 285 to dynamically control the optimal distance between the suction gun assembly 28 and the detection surface, and by using the closed detection environment to isolate external interference, the reliability of the battery pack 5 air tightness detection is improved, and the missed detection rate is reduced.

[0027] Please refer to Figures 1 to 6 The preferred embodiment of the battery pack air tightness helium detection system of the present application comprises: A helium mixing station 1 for filling helium into the battery pack 5; A helium detection station 2 for detecting whether the battery pack 5 has leaked helium, and further judging the air tightness; A Pack trolley 3 for transplanting the battery pack 5; A cover box helium detection tool 4 arranged at the top end of the Pack trolley 3 for assisting the battery pack 5 in injecting helium; A host computer (not shown) connected with the helium mixing station 1, the helium detection station 2 and the Pack trolley 3 respectively, for controlling the work of the battery pack air tightness helium detection system; The helium mixing station 1 comprises: A helium mixing frame 11 for bearing the helium mixing station 1; At least one helium mixing cabinet 12 arranged at the top end of the helium mixing frame 11 and connected with the host computer, for diluting pure helium into helium-nitrogen mixed gas which is cost-effective and can meet the detection requirements, and for filling the mixed gas into the battery pack 5 at a controlled pressure and flow rate, so as to prepare a tracer gas source for subsequent leakage detection, and to provide a gas with stable concentration and pressure, thereby laying a foundation for high precision and reliability of the entire detection system; A plurality of helium cylinders 13 arranged at the side of the helium mixing frame 11 for supplementing helium to the helium mixing cabinet 12; At least one helium filling pipeline 14 having an input end in communication with the output end of the helium mixing cabinet 12, for connecting the helium mixing cabinet 12 and the cover box helium detection tool 4; The helium detection station 2 comprises: An external equipment frame 21 provided with a roller shutter door 211; the external equipment frame 21 is used for bearing the helium detection station 2; A control panel 22 arranged at the side of the external equipment frame 21 and connected with the host computer, for controlling the work of the helium detection station 2; At least one helium exhaust module 23 is arranged at the top end of the equipment outer frame 21, is in communication with the inside of the equipment outer frame 21, and is connected with the control panel 22; helium is a colorless and odorless inert gas, and a large amount of leakage and accumulation in a closed or poorly ventilated work station can cause an oxygen-deficient environment, posing a serious threat to the life safety of on-site operators, so the helium exhaust module 23 is arranged to prevent helium accumulation; A jacking mechanism 24 is arranged in the inside of the equipment outer frame 21 and is connected with the control panel 22, and is used for positioning and jacking the Pack trolley 3; A helium detector 25 is arranged in the inside of the equipment outer frame 21 and is connected with the control panel 22, and is used for detecting whether there is helium and the content of helium; A robot 26 is arranged in the inside of the equipment outer frame 21 through a walking shaft 261 and is connected with the control panel 22, and is used for controlling the suction gun assembly 28 to perform helium detection on the battery pack 5; A calibration assembly 27 is arranged in the inside of the equipment outer frame 21 and is connected with the control panel 22, and is used for calibration of the suction gun assembly 28; A suction gun assembly 28 is arranged at the end of the mechanical arm of the robot 26 and is connected with the control panel 22, and is used for performing helium detection.

[0028] The calibration assembly 27 comprises: An installation plate 271 is arranged in the inside of the equipment outer frame 21 and is provided with at least one active leak hole 2711 (for calibration of the helium detection gun) and one passive leak hole 2712 (for spot detection of the helium detection gun); A suction gun position detection sensor 272 is arranged on the installation plate 271 and is connected with the control panel 22; At least one calibration cover box 273 is arranged on the installation plate 271; the calibration cover box 273 is used as a "standard weight", that is, a known standard leakage rate is used to calibrate the entire leak detection system, to ensure that the reading is accurate; A laser ranging calibration block 274 is arranged on the installation plate 271; A camera calibration plate 275 is arranged on the installation plate 271; A robot calibration piece 276 is arranged on the installation plate 271.

[0029] The suction gun assembly 28 comprises: A mounting bracket 281 is arranged at the end of the mechanical arm of the robot 26; A camera 282 is arranged on the mounting bracket 281 and is connected with the control panel 22; A helium leak detector 284 is arranged on the mounting rack 281 and connected with the helium detector 25. A helium leak detector 284 is arranged on the mounting rack 281 and connected with the helium detector 25. A laser range finder 285 is arranged on the mounting rack 281 and connected with the control panel 22, used for detecting the distance from the battery pack 5. An impact alarm assembly 286 is arranged on the mounting rack 281 and connected with the control panel 22, used for issuing sound and light alarm when impact occurs or is about to occur.

[0030] The preferred embodiment of the battery pack airtight helium detection method of the application comprises the following steps: Step S1, place the battery pack in the cover box helium detection tool, and transplant the cover box helium detection tool to the helium mixing station through the Pack trolley; Step S2, connect the exhaust port of the cover box helium detection tool with the connector of the battery pack, connect the inflation port with the helium filling pipeline, and sequentially fill helium into the battery pack through the helium mixing cabinet, the helium filling pipeline and the cover box helium detection tool, then remove the helium filling pipeline, and the inflation port of the cover box helium detection tool is automatically sealed; Step S3, open the roller shutter door of the helium detection station, transplant the cover box helium detection tool to the jacking mechanism of the helium detection station through the Pack trolley, position and jack through the jacking mechanism, and then close the roller shutter door; Step S4, move the suction gun assembly to the calibration assembly by the robot to perform calibration operation, after calibration is completed, move the suction gun assembly around the battery pack at a preset speed through the linkage of the walking shaft and the mechanical arm, and detect the airtightness of the battery pack through the helium detector. Before detection, the battery pack is positioned through the camera, guided by the vision of the camera, the suction gun assembly detects the battery pack at a preset speed (such as 200 mm / s, 60 mm / s) with a distance of 4±1 mm from the bolts and edges of the battery pack, and the airtightness is judged through the detection value of the helium detector.

[0031] In summary, the application has the following advantages: 1. By adopting the high-sensitivity helium mass spectrometry leak detection method, and combining with the robot carrying the suction gun assembly to automatically scan the battery pack along the preset path, the precise capture and positioning of the tiny leakage points are realized; at the same time, the calibration assembly is integrated for real-time calibration before detection, the laser range finder is used for dynamic control of the optimal distance between the suction gun and the detection surface, and the closed detection environment is used for isolation of external interference, so as to systematically improve the stability of the detection process and the repeatability of the results, significantly reduce the risk of misjudgment and missed detection, and greatly improve the reliability of the battery pack airtight detection and greatly reduce the missed detection rate.

[0032] 2. The host computer controls the helium mixing station, helium testing station, and pack cart in a unified manner, realizing centralized management and automated operation of the entire testing process. This integrated design reduces manual intervention, improves testing efficiency, and reduces the risk of operational errors. The collaborative work between the various stations ensures a seamless connection between helium filling and testing of the battery pack, which is particularly suitable for large-scale production lines and improves the overall production rhythm and consistency.

[0033] 3. The helium testing station is equipped with calibration components and suction gun components, including active leak orifice, passive leak orifice, camera, laser rangefinder, etc., which can be automatically calibrated before testing to ensure the accuracy and repeatability of the helium detector; the robot, driven by the walking axis and the robotic arm, can move the suction gun components at a preset speed with precision, avoiding human operation deviation, thereby achieving high-precision testing of the airtightness of the battery pack and meeting strict quality standards.

[0034] 4. Helium is used as the detection medium. Helium is an inert gas that is non-toxic and harmless, avoiding the safety risks that may be caused by traditional detection methods. At the same time, the helium detection station is equipped with a helium discharge module, which can promptly handle and recover residual helium, reducing the environmental impact of gas leaks. The automatic sealing design of the cover helium detection fixture further prevents helium from escaping, meeting the environmental protection requirements of modern manufacturing.

[0035] 5. The system can adapt to the testing needs of battery packs of different sizes and shapes through robots and mobile pack carts; the various sensors and calibration components in the calibration assembly (such as laser rangefinder calibration blocks and camera calibration boards) allow the system to quickly adjust parameters to adapt to different production conditions. This modular design makes the system easy to expand or modify, and facilitates future technology upgrades or production line adjustments.

[0036] 6. The control panel and host computer provide an intuitive user interface, allowing operators to easily monitor detection status and parameters and adjust processes in real time; the design of the roller shutter door and lifting mechanism simplifies the loading and unloading of battery packs, reducing manual labor; safety features such as impact alarm components further reduce the risk of equipment damage, improving user experience and maintenance convenience.

[0037] 7. Automated processes significantly reduce manpower requirements and testing time, thereby reducing long-term operating costs; centralized management of helium supply at the helium mixing station avoids gas waste; and the robotic testing at the helium inspection station offers fast and consistent testing, reducing repetitive work and scrap rates.

[0038] 8. The calibration component integrates multiple tools such as active orifice, passive orifice, and suction gun position detection sensor, allowing for comprehensive self-calibration before testing to ensure data accuracy. This design solves the cumbersome calibration problem commonly found in traditional helium testing, improving the reliability and efficiency of testing.

[0039] 9. Through the host computer centralized control of helium mixing, helium detection station and Pack trolley, the full process automation and high integration of helium filling, transplanting, positioning and detection are realized, and the detection efficiency and consistency are significantly improved; the system ensures the high precision and reliability of the air tightness detection by means of the robot driving suction gun assembly combined with the precise calibration mechanism (such as laser ranging, active / passive leak hole calibration); at the same time, helium is used as a safety medium and is equipped with helium exhaust and automatic sealing design, which takes into account the environmental protection and operation safety, and the overall scheme improves the detection quality and automation level while having good adaptability and cost effectiveness.

[0040] Although the specific embodiments of the present application are described above, those skilled in the art should understand that the specific examples described are only illustrative, and are not intended to limit the scope of the present application, and equivalent modifications and changes made by those skilled in the art in accordance with the spirit of the present application should be covered within the scope of the claims of the present application.

Claims

1. A battery pack airtight helium detection system, characterized in that: include: A helium mixing station; A helium testing station; A small pack cart; A helium detection fixture is mounted on top of the Pack trolley; A host computer is connected to the helium mixing station, the helium testing station, and the Pack cart, respectively. The helium mixing station includes: A helium mixing framework; At least one helium mixing cabinet is located at the top of the helium mixing frame and connected to the host computer; Several helium cylinders are located on the side of the helium mixing frame; At least one helium filling pipeline, with its input end connected to the output end of the helium mixing cabinet; The helium testing station includes: An external frame for the equipment, equipped with a roller shutter door; A control panel is located on the side of the outer frame of the device and is connected to the host computer; At least one helium exhaust module is located at the top of the outer frame of the device, communicates with the interior of the outer frame of the device, and is connected to the control panel; A lifting mechanism is located inside the outer frame of the equipment and connected to the control panel; A helium detector is located inside the outer frame of the device and connected to the control panel; A robot is mounted inside the outer frame of the device via a walking axis and is connected to the control panel; A calibration component is located inside the outer frame of the device and connected to the control panel; A suction gun assembly is located at the end of the robot's robotic arm and is connected to the control panel.

2. The battery pack gas tightness helium detection system as described in claim 1, characterized in that: The calibration components include: A mounting plate is located inside the outer frame of the device and has at least one active drain hole and one passive drain hole; A suction gun position detection sensor is mounted on the mounting plate and connected to the control panel; At least one calibration cover is disposed on the mounting plate; A laser ranging calibration block is mounted on the mounting plate; A camera calibration plate is mounted on the mounting plate; A robot calibration component is mounted on the mounting plate.

3. The battery pack gas tightness helium detection system as described in claim 1, characterized in that: The suction gun assembly includes: A mounting bracket is provided at the end of the robot's robotic arm; A camera is mounted on the mounting bracket and connected to the control panel; A helium cleaning gun is mounted on the mounting bracket and connected to the control panel; A helium detection gun is mounted on the mounting bracket and connected to the helium detector; A laser rangefinder is mounted on the mounting bracket and connected to the control panel; An impact alarm component is mounted on the mounting bracket and connected to the control panel.

4. A method for detecting the gas tightness of a battery pack using helium, characterized in that: The method requires the use of the battery pack gas tightness helium detection system as described in any one of claims 1 to 3, and includes the following steps: Step S1: Place the battery pack inside the helium testing fixture and transfer the helium testing fixture to the helium mixing station using the Pack cart. Step S2: Connect the vent of the cover helium inspection fixture to the connector of the battery pack, and connect the filling port to the helium filling pipeline. Fill the battery pack with helium through the helium mixing cabinet, the helium filling pipeline and the cover helium inspection fixture in sequence. Then remove the helium filling pipeline and the filling port of the cover helium inspection fixture will automatically seal. Step S3: Open the roller shutter door of the helium inspection station, and use the Pack trolley to transfer the helium inspection fixture to the lifting mechanism of the helium inspection station. Position and lift the fixture using the lifting mechanism, and then close the roller shutter door. Step S4: The robot moves the suction gun assembly to the calibration assembly to perform the calibration operation. After calibration, the suction gun assembly moves around the battery pack at a preset speed through the walking axis and the robotic arm, and the airtightness of the battery pack is tested by the helium detector.

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