Battery detection system and method thereof, single battery, battery pack, battery pack, electric vehicle

Abstract

This application discloses a battery testing system and method, a single battery cell, a battery pack, a battery module, and an electric vehicle, relating to the field of battery testing technology. The system includes a radiation source device and a detector connected to the radiation source device. The radiation source device is used to perpendicularly irradiate at least one side of the battery with the radiation source device's radiation optical center aligned, thereby performing radiation imaging on the battery. The detector is used to collect radiation imaging data, generate original projected images of at least one battery side based on the radiation imaging data, and determine a comprehensive imaging image of the battery based on multiple original projected images corresponding to multiple battery sides. This solves the technical problems of insufficient detection accuracy and difficulty in eliminating edge blind spots in battery testing systems during radiation imaging. It achieves the elimination of battery edge imaging blind spots without increasing equipment cost or testing time.

Description

Technical Field

[0001] This application relates to the field of battery testing technology, and more specifically, to a battery testing system and method, a single cell, a battery pack, a battery module, and an electric vehicle. Background Technology

[0002] With the widespread application of new energy power batteries in electric vehicles, energy storage systems, and other fields, their safety and manufacturing quality are directly related to the service life and safety of end products. During the production process, lithium batteries may develop microscopic defects such as misaligned tabs, internal microcracks, foreign matter inclusions, and separator wrinkles. These defects are difficult to detect in conventional electrical performance tests, but may induce thermal runaway during long-term charge-discharge cycles, causing serious safety accidents.

[0003] In related technologies, X-rays penetrate the battery body to form a two-dimensional projection image on a planar detector, and internal anomalies are identified by differences in image grayscale. However, traditional single-view X-ray imaging has a significant edge blind zone problem when inspecting prismatic or cylindrical lithium batteries, which seriously affects the defect detection rate. Specifically, due to the geometric distortion of the cone-beam projection, the edge region of the lithium battery forms a transition / blurred region in the two-dimensional X-ray imaging, resulting in decreased resolution, reduced signal-to-noise ratio, and difficulty in identifying defects in this area. Furthermore, the current radiographic mode at the workstation cannot eliminate this blind zone, and the cost and efficiency of three-dimensional computed tomography (CT) scanning do not meet the requirements of full inspection on the production line.

[0004] It is evident that X-ray imaging suffers from technical problems such as insufficient detection accuracy and difficulty in eliminating edge blind zones.

[0005] In the relevant technologies, battery detection systems suffer from insufficient detection accuracy and difficulty in eliminating edge blind zones during X-ray imaging, and no effective solution has yet been proposed. Summary of the Invention

[0006] This application provides a battery detection system and method, a single cell, a battery pack, a battery module, and an electric vehicle, to at least solve the technical problems of insufficient detection accuracy and difficulty in eliminating edge blind spots in related technologies when using X-ray imaging.

[0007] According to one embodiment of this application, a battery inspection system is provided, comprising: a radiation source device and a detector connected to the radiation source device; wherein, the radiation source device is used to perpendicularly irradiate at least one battery side with the radiation source device aligned with the radiation optical center of the radiation source device, so as to perform radiation imaging on the battery; the detector is used to acquire radiation imaging data of the at least one battery side, generate an original projection image of the at least one battery side based on the radiation imaging data, and determine a comprehensive imaging map corresponding to the battery based on multiple original projection images corresponding to multiple battery sides on the battery, wherein the comprehensive imaging map is used for non-destructive testing of the battery.

[0008] In an exemplary embodiment, the battery detection system further includes: a battery fixture platform; the battery fixture platform is used to fix the battery and determine the battery detection trajectory corresponding to the target size of the battery and the operating parameters of the X-ray source device, wherein the target size includes at least one of the following: the length of the battery, the width of the battery, and the thickness of the battery.

[0009] In one exemplary embodiment, the battery tooling platform further includes: a workstation turntable for controlling the rotation of the battery at different angles; and a clamping mechanism mounted on the workstation turntable for securing the battery and performing planar translation and angle correction on the battery.

[0010] In an exemplary embodiment, the battery fixture platform further includes: a parameter preset module for storing the association between reference dimensions of multiple types of batteries and multiple reference trajectories corresponding to the battery fixture platform; a calling module connected to the parameter preset module for determining the detection trajectory to be executed by the battery fixture platform based on the target size, and determining the operating parameters of the X-ray source device corresponding to the detection trajectory, wherein the detection trajectory is used to indicate the rotation angle of the battery fixture platform; and a platform communication module connected to the X-ray source device for synchronizing the operating parameters to the X-ray source device.

[0011] In one exemplary embodiment, the detector further includes: a defect identification module connected to a battery tooling platform, configured to determine a preset standard imaging image to be invoked based on the target size of the battery, identify image differences between the preset standard imaging image and the composite imaging image, and determine whether the battery has defects based on the image differences.

[0012] In an exemplary embodiment, the detector further includes a defect determination module connected to the defect identification module, configured to detect and verify the defect according to a preset determination logic when the battery is determined to have a defect based on the image differences. The preset determination logic includes at least one of the following: if the same defect appears repeatedly on the side of the battery in at least two original projection images, the verification result is that the battery has a defect; if the defect appears only on the side of the battery in one original projection image and not in other original projection images, the verification result is that the battery does not have a defect.

[0013] In an exemplary embodiment, the detector further includes: a detection result module connected to the defect determination module, configured to output a first detection result indicating that the battery is a non-destructive battery when the detection verification result indicates that the battery has a defect; and to output a second detection result indicating that the battery is a non-destructive battery when the detection verification result indicates that the battery does not have a real defect.

[0014] In one exemplary embodiment, the detector further includes: an image registration module, used to spatially align the original projected images corresponding to multiple battery sides based on a preset image registration algorithm to obtain target projected images corresponding to the at least one battery side respectively.

[0015] In one exemplary embodiment, the detector further includes an image fusion module connected to the image registration module, used to fuse the multiple target projection images to generate a composite image.

[0016] In an exemplary embodiment, the battery testing system further includes: a testing control module, configured to record the testing duration of the battery, and if the testing duration exceeds a preset testing duration, determine that the battery testing process is abnormal and send an alarm message to the management object associated with the battery testing system; and a testing statistics module, configured to determine that the battery testing process is normal if the testing duration is less than or equal to the preset testing duration, and count the number of batteries with normal testing processes that have been produced.

[0017] According to another aspect of the embodiments of this application, a battery inspection method is also provided, comprising: when at least one battery side of a battery is aligned with the optical center of a radiation source device, controlling the radiation source device to vertically irradiate the at least one battery side through a radiation source, and instructing a detector connected to the radiation source device to acquire radiation imaging data of the at least one battery side; determining an original projection image of the at least one battery side based on the radiation imaging data, and determining a comprehensive imaging map corresponding to the battery based on multiple original projection images corresponding to multiple battery sides on the battery; and performing non-destructive testing on the battery based on the comprehensive imaging map.

[0018] According to another aspect of the embodiments of this application, a computer-readable storage medium is also provided, wherein a computer program is stored in the computer program, and the computer program is configured to execute the battery detection method of the battery detection system described above when it is run.

[0019] According to another aspect of the embodiments of this application, an electronic device is also provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the battery detection method of the battery detection system described above through the computer program.

[0020] According to another aspect of the embodiments of this application, a computer program product is also provided, including a computer program that, when executed by a processor, implements the battery detection method of the battery detection system described above.

[0021] According to another aspect of the embodiments of this application, a single cell battery is also provided, including a non-destructive cell battery, which is a battery that is determined to be free of defects after being subjected to X-ray inspection by a battery testing system.

[0022] According to another embodiment of the present application, a battery pack is also provided, including at least two batteries of the above embodiments, each battery being electrically connected to the other.

[0023] According to another embodiment of the present application, a battery pack is also provided, including a housing and at least two battery packs of the above embodiments, each battery pack being disposed in the housing and electrically connected to each other.

[0024] According to yet another embodiment of the present application, an electric vehicle is also provided, including the battery pack of the above embodiment.

[0025] In this embodiment, when at least one side of the battery is precisely aligned with the central axis of the X-ray source device, the X-ray source device is controlled to irradiate the battery side in a vertical incident manner, and a connected planar detector is simultaneously triggered to collect X-ray imaging data of that side. The alignment imaging step is repeated on multiple sides of the battery in sequence to obtain multiple original projection images corresponding to the multiple sides of the battery. A comprehensive imaging map covering the entire side area of ​​the battery is constructed based on the multiple original projection images. Based on the comprehensive imaging map, automatic defect identification of the internal structure of the battery is performed to achieve non-destructive testing of the battery. By adopting the above technical solution, the technical problems of insufficient detection accuracy and difficulty in eliminating edge blind spots in the X-ray imaging of the battery detection system are solved. It achieves complete elimination of the edge X-ray imaging blind spot of the battery without increasing equipment cost and detection time, improves the edge defect identification rate, avoids the increase in detection cost, and ensures the detection accuracy of online full detection. Attached Figure Description

[0026] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a structural block diagram of a battery detection system according to an embodiment of this application;

[0029] Figure 2 This is a schematic flowchart of a battery detection method according to an embodiment of this application;

[0030] Figure 3 This is a schematic diagram of the hardware structure of a battery detection system according to an embodiment of this application;

[0031] Figure 4 This is a schematic diagram of the detection principle of the battery detection system according to an embodiment of this application;

[0032] Figure 5 This is a schematic diagram of the detection principle of bilateral irradiation according to an embodiment of this application;

[0033] Figure 6 This is a schematic diagram of a four-position battery detection according to an embodiment of this application;

[0034] Figure 7 This is a schematic diagram of the multi-sided illumination detection principle according to an embodiment of this application. Detailed Implementation

[0035] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0036] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0037] The following appropriately discloses an embodiment of a battery according to this application. However, unnecessary detailed descriptions may be omitted. For example, detailed descriptions of well-known matters and repetitive descriptions of practically identical structures may be omitted. This is to avoid making the following description unnecessarily lengthy and to facilitate understanding by those skilled in the art. Furthermore, the following description is provided to enable those skilled in the art to fully understand this application and is not intended to limit the subject matter of the claims.

[0038] The battery cell in this application is a secondary battery, also known as a rechargeable battery or accumulator, which refers to a battery that can be recharged after discharge to activate the active materials and continue to be used. Typically, a secondary battery includes an electrode assembly, an electrolyte, and an outer casing. The electrode assembly includes a positive electrode, a negative electrode, and a separator. The electrode assembly and electrolyte are assembled inside the outer casing. During battery charging and discharging, active ions (such as lithium ions) move back and forth between the positive and negative electrodes, inserting and extracting. The separator is located between the positive and negative electrodes, primarily serving to prevent short circuits between the positive and negative electrodes while allowing active ions to pass through. The electrolyte, located between the positive and negative electrodes, primarily serves to conduct active ions.

[0039] As an example, the preparation process of a secondary battery is as follows: the positive electrode, separator, and negative electrode are stacked in sequence, with the separator acting as a separator between the positive and negative electrodes. Then, the electrodes are wound or stacked to obtain an electrode assembly. The electrode assembly is placed in an outer packaging shell, dried, and then injected with electrolyte. After vacuum sealing, settling, formation, and shaping, a secondary battery is obtained.

[0040] As an optional implementation method, Figure 1 This is a structural block diagram of a battery detection system according to an embodiment of this application; as shown... Figure 1 As shown, it includes:

[0041] X-ray source device 12, and detector 14 connected to X-ray source device 12;

[0042] The X-ray source device 12 is used to vertically irradiate at least one side of the battery when the battery side is aligned with the X-ray optical center of the X-ray source device, so as to perform X-ray imaging on the battery.

[0043] Detector 14 is used to acquire X-ray imaging data of at least one side of the battery, generate an original projection image of at least one side of the battery based on the X-ray imaging data, and determine a comprehensive imaging map of the battery based on multiple original projection images corresponding to multiple battery sides on the battery. The comprehensive imaging map is used for non-destructive testing of the battery.

[0044] Taking a square battery with four sides as an example, when any side of the battery is precisely aligned with the center of the cone beam of the X-ray source device 12 using a positioning fixture, the X-ray source 12 penetrates that side in a nearly perpendicular manner, i.e., the incident angle is ≤1°. This effectively avoids the distortion problems caused by tilted incident light, such as image stretching, magnification, and extended penetration path, in traditional cone beam projection. At this time, the detector 14 connected to it simultaneously acquires high signal-to-noise ratio and high-resolution X-ray imaging data and generates the original projection image of that side. Subsequently, the above alignment imaging process is repeated for each of the four sides of the battery to obtain four clear original images corresponding to different edges. Through image registration, contrast enhancement, and multi-scale fusion algorithms, these four images are precisely stitched into a comprehensive imaging image covering all four sides of the battery. This image transforms the blurry areas at the edge of the field of view into a high-fidelity area in the center, thereby enabling comprehensive and accurate visualization and identification of minute defects such as tab misalignment, diaphragm wrinkles, and microcracks during the non-destructive testing stage through the comprehensive imaging image.

[0045] The aforementioned battery inspection system, with at least one side of the battery precisely aligned with the cone-beam optical axis of the X-ray source device, controls the X-ray source device to irradiate the battery side in a vertical incident manner, and simultaneously triggers the connected planar detector to acquire X-ray imaging data of that side. The alignment imaging step is repeated sequentially on multiple sides of the battery to obtain multiple original projection images corresponding to each side. Based on these multiple original projection images, a comprehensive imaging map covering the entire side area of ​​the battery is constructed. Based on the comprehensive imaging map, automatic defect identification of the battery's internal structure is performed to achieve non-destructive testing of the battery. This technical solution solves the problems of insufficient detection accuracy and difficulty in eliminating edge blind zones in X-ray imaging of battery inspection systems. It achieves complete elimination of X-ray imaging blind zones at battery edges without increasing equipment costs or inspection time, improving edge defect identification rates, avoiding increased inspection costs, and ensuring the accuracy of online full-inspection.

[0046] In one exemplary embodiment, the battery inspection system further includes: a battery fixture platform; the battery fixture platform is used to fix the battery and determine the battery inspection trajectory corresponding to the target size of the battery and the operating parameters of the X-ray source device, wherein the target size includes at least one of the following: the length of the battery, the width of the battery, and the thickness of the battery.

[0047] Optionally, the battery testing system is equipped with a battery tooling platform. This platform not only stably fixes the battery to be tested through a mechanical clamping structure to prevent displacement or vibration during the testing process, but also has size recognition and adaptive functions. That is, according to the target size of the battery, such as length, width or thickness and other key parameters, it matches the preset detection trajectory and X-ray source operating parameters, such as the four-station rotation angle, translation path, distance from X-ray source to battery (FOD), distance from X-ray source to detector (FDD), and exposure time, to ensure that batteries of different specifications can achieve precise edge alignment and optimal imaging conditions in each test. This enables flexible and high-precision testing of multiple battery models without manual intervention, greatly improving the compatibility of testing and the adaptability of production lines.

[0048] Optionally, the battery tooling platform may also include: a workstation turntable for controlling the rotation of the battery at different angles; and a clamping mechanism mounted on the workstation turntable for securing the battery and performing planar translation and angle correction on the battery.

[0049] In other words, the battery tooling platform is equipped with a station turntable and a clamping mechanism. The station turntable can precisely control the angle rotation of the battery between different inspection stations to ensure that each side of the battery is aligned with the X-ray optical center in sequence, achieving vertical incident imaging. The clamping mechanism is installed above the turntable and adopts an adaptive gripper or vacuum adsorption structure. While fixing the battery, it can sense and compensate for the battery's planar position offset and slight angular tilt in real time, complete the planar translation and angular correction of the battery, and ensure the geometric alignment accuracy of each imaging, thereby completely eliminating projection offset or blind spot residue caused by clamping errors.

[0050] Optionally, the battery fixture platform further includes: a parameter preset module for storing the association between reference dimensions of multiple types of batteries and multiple reference trajectories corresponding to the battery fixture platform; a calling module connected to the parameter preset module for determining the detection trajectory to be executed by the battery fixture platform based on the target size, and determining the operating parameters of the X-ray source device corresponding to the detection trajectory, wherein the detection trajectory is used to indicate the rotation angle of the battery fixture platform; and a platform communication module connected to the X-ray source device for synchronizing the operating parameters to the X-ray source device.

[0051] In other words, the battery testing system is equipped with a battery tooling platform. This platform can measure the target dimensions of the battery under inspection, such as length, width, and thickness, in real time using high-precision sensors. Based on a built-in parameter preset module, it automatically matches a database of pre-stored reference dimensions for various battery types with corresponding optimal detection trajectories and X-ray source operating parameters. These operating parameters include, but are not limited to, databases of tube voltage, tube current, exposure time, and focal length. The system determines the station rotation and translation path that the current battery should execute through a calling module, and the platform communication module synchronizes the operating parameters to the X-ray source equipment and detector in real time to ensure optimal imaging conditions. The station turntable can control the battery to rotate at a predetermined angle, enabling each side to be aligned with the X-ray optical center sequentially. The clamping mechanism integrated on the turntable has planar micro-movement and micro-angle correction functions, which can compensate for battery clamping deviations. This improves the accuracy of each alignment without relying on manual adjustments, achieving automated adaptation and precise detection control for different types of batteries.

[0052] In one exemplary embodiment, the detector further includes: a defect identification module connected to a battery tooling platform, configured to determine a preset standard imaging image to be invoked based on the target size of the battery, identify image regions where the composite imaging image differs from the preset standard imaging image, and determine whether the battery is allowed to enter the subsequent production process based on the size of the image regions.

[0053] Optionally, the detector further includes: a detection module connected to the defect identification module, configured to prevent the battery from entering the subsequent production process and output a first detection result indicating that the battery is a non-destructive battery when the area size is larger than the preset safety area size; and to allow the battery to enter the subsequent production process and output a second detection result indicating that the battery is a non-destructive battery when the area size is smaller than or equal to the preset safety area size.

[0054] In short, the detector integrates a defect identification module. This module communicates with the battery tooling platform in real time to acquire the target dimensions of the battery to be inspected. Based on the target dimensions, such as length, width, and thickness, it calls up a preset standard imaging image corresponding to that battery model. The preset standard imaging image is generated by statistical averaging and feature enhancement of a large number of qualified product imaging images, fully representing the normal distribution of the internal structure of the battery of this specification. Subsequently, the real-time acquired comprehensive imaging image is compared with the preset standard imaging image at the pixel level to accurately identify areas of difference in grayscale, edges, texture, or structure. The area of ​​the difference area is then calculated. The detection module receives this area data. If it exceeds the size of a preset safety area, it is determined to have an unacceptable defect, outputs the first detection result for a non-destructive battery, and triggers an interception signal to prevent the battery from entering the next process. If the area of ​​the difference area is less than or equal to the size of the preset safety area, the current battery is determined to meet the quality requirements, outputs the second detection result for a non-destructive battery, and allows the battery to continue to circulate.

[0055] In an exemplary embodiment, the detector is further configured to correspond the multiple original projected images one-to-one with different sides of the battery, and obtain side detection parameters configured for the non-destructive testing by the system management object; wherein the side detection parameters include at least: the number of sides and the type of sides; the number of sides is an integer greater than or equal to 2; select multiple target original projected images from the multiple original projected images based on the side detection parameters; and load the multiple target original projected images onto the same interface for display.

[0056] Understandably, after acquiring multiple raw projection images, the detector establishes a one-to-one correspondence between each image and a specific side of the battery, filtering them according to the side detection parameters configured for the current non-destructive testing event in the system management object. These side detection parameters include at least the number of sides and the side type, where the number of sides is an integer greater than or equal to 2, and the side type is used to identify whether the corresponding side of the battery is a long side or a short side. Based on these side detection parameters, the detector selects multiple target images from all raw projection images that match the specified number and type of sides. For example, when the battery is quadrilateral, it has four sides, so four images corresponding to the four sides of the battery are selected. Then, these selected target raw projection images are uniformly loaded onto the same display interface for subsequent image registration and comprehensive analysis.

[0057] Optionally, for quadrilateral batteries, if 2 or 3 side detection parameters can meet production quality requirements, for the case of two sides, two long sides or two short sides of the battery, or two adjacent sides, can be selected. Then, the target original projection images corresponding to these sides can be selected, and the two target original projection images can be loaded onto the same display interface. For the case of three sides, three adjacent sides of the battery can be selected. If the battery is pentagonal, two adjacent sides and at least one of the remaining sides can also be selected. It should be noted that the above is merely an example and does not limit the battery shape of this application.

[0058] In one exemplary embodiment, the detector further includes: an image registration module, configured to spatially align the multiple original projection images of the targets based on a preset image registration algorithm to obtain multiple aligned images before loading the multiple original projection images of the targets onto the same interface for display; and input the multiple aligned images into a trained local deformation compensation model to generate multiple images to be fused.

[0059] The detector is further equipped with an image registration module. Before loading multiple original projection images of targets onto the same display interface, the image registration module first performs spatial coordinate alignment on each image based on a preset image registration algorithm, such as SIFT based on feature point matching or a non-rigid registration algorithm based on mutual information. This eliminates differences in image displacement and rotation caused by battery placement posture, tooling micro-movement, or relative deviation between the X-ray source and the detector, generating a set of aligned images with consistent spatial positions. Subsequently, these aligned images are input into a trained local deformation compensation model. This model learns the local deformation rules of different sides under tilted projection caused by geometric stretching, edge blurring, and thickness effects through a deep learning network. It automatically corrects the residual non-uniform distortion in each image, generating images to be fused with structural consistency and geometric fidelity.

[0060] In an exemplary embodiment, the detector further includes: an image fusion module connected to the image registration module, configured to perform fusion processing on the plurality of images to be fused to generate a comprehensive imaging map, wherein the comprehensive imaging map is obtained by selecting the target side corresponding to the original projection image of the target on the side distribution diagram corresponding to the battery, and filling the side distribution diagram with the image to be fused corresponding to the original projection image of the target, thereby obtaining an imaging map corresponding to the battery, wherein the fusion processing includes: assigning the highest weight to the central region of each side on each image to be fused, and gradually decreasing the weight of the edge regions other than the central region according to a preset attenuation index to obtain multiple sets of weight change data; performing similar fusion on the images to be fused based on the multiple sets of weight change data; performing multi-scale fusion on the overlapping region of any two images to be fused based on the multiple sets of weight change data; and performing contrast enhancement and edge sharpening processing on any image to be fused based on the multiple sets of weight change data.

[0061] In short, the detector is also equipped with an image fusion module connected to the image registration module. This module performs multi-scale fusion processing on multiple images to be fused after registration and deformation compensation, generating a comprehensive imaging map reflecting the overall structure of the battery. The image fusion module first spatially maps each image to be fused to its corresponding side (e.g., front, back, left, right) based on the battery side distribution diagram, using the area of ​​that side in the diagram as the filling target. During the fusion process, the central region of each side in each image to be fused is assigned the highest weight, ensuring that information from key regions dominates the output, while information from edge regions far from the center is weighted down. The weights of each region are gradually reduced according to a preset Gaussian or exponential decay function, forming a weight distribution map that changes point by point. Then, multi-scale pyramid fusion is performed on the overlapping areas between adjacent images to be fused using this multi-set weight data. By decomposing different frequency components and combining the weights to select the optimal details, abrupt changes in brightness or structural misalignment at the stitching boundary are avoided. At the same time, contrast enhancement and edge sharpening operations are applied to each image to be fused to enhance the grayscale contrast and contour clarity of minor defects. Finally, while maintaining the structural integrity of each side, a comprehensive image that is spatially continuous, uniformly contrasted, and rich in detail is generated.

[0062] In an exemplary embodiment, the battery testing system further includes: a testing control module, used to record the testing duration of the battery, and if the testing duration exceeds a preset testing duration, to determine that the battery testing process is abnormal and to send an alarm message to the management object associated with the battery testing system; and a testing statistics module, used to determine that the battery testing process is normal if the testing duration is less than or equal to the preset testing duration, and to count the number of batteries that have been produced with normal testing processes.

[0063] Optionally, the battery testing system is also equipped with a testing control module and a testing statistics module to achieve comprehensive control of the testing process and battery production capacity recording. Specifically, the testing control module collects the entire testing time of each battery from loading and positioning to image acquisition completion in real time and compares it with the preset standard testing time. If the testing time exceeds the limit, such as due to abnormal X-ray source power, detector response delay, tooling positioning jamming, or increased friction of the moving mechanism, the testing process is immediately determined to be abnormal, and an alarm mechanism is automatically triggered to send maintenance alarm information containing equipment code, abnormal timestamp, timeout type, and possible fault source to production line managers and equipment maintenance personnel, realizing rapid response and preventive maintenance in the battery production process. Under the premise that the testing time meets the standard, the testing statistics module automatically includes the battery in the statistical pool of batteries that have passed the normal process, and accumulates the number of qualified batteries that have successfully completed non-destructive testing, providing data support for battery production capacity planning and quality traceability.

[0064] This embodiment provides a battery detection method, such as Figure 2 As shown, Figure 2 This is a schematic flowchart of a battery detection method according to an embodiment of this application, including the following steps:

[0065] Step S202: When at least one battery side of the battery is aligned with the optical center of the X-ray source device, control the X-ray source device to vertically irradiate the at least one battery side through the X-ray source, and instruct the detector connected to the X-ray source device to collect X-ray imaging data of the at least one battery side.

[0066] Step S204: Determine the original projection image of the at least one battery side based on the ray imaging data, and determine the comprehensive imaging image corresponding to the battery based on the multiple original projection images corresponding to the multiple battery sides on the battery.

[0067] Step S206: Perform non-destructive testing on the battery based on the comprehensive imaging image.

[0068] Through the above steps, with at least one side of the battery precisely aligned with the cone-beam optical axis of the X-ray source device, the X-ray source device is controlled to irradiate the battery side in a vertical incident manner, and simultaneously triggers the connected planar detector to acquire X-ray imaging data of that side. The alignment imaging step is repeated for multiple sides of the battery in sequence to obtain multiple original projection images corresponding to multiple sides of the battery. Based on the multiple original projection images, a comprehensive imaging map covering the entire side area of ​​the battery is constructed. Based on the comprehensive imaging map, automatic defect identification of the internal structure of the battery is performed to achieve non-destructive testing of the battery. By adopting the above technical solution, the technical problems of insufficient detection accuracy and difficulty in eliminating edge blind zones in the X-ray imaging of battery inspection systems are solved. It achieves complete elimination of X-ray imaging blind zones at the battery edge without increasing equipment costs and inspection time, thereby improving the edge defect identification rate, avoiding the increase in inspection costs, and ensuring the detection accuracy of online full inspection.

[0069] Optionally, non-destructive testing of the battery based on the comprehensive imaging image includes: determining a preset standard imaging image to be used according to the target size of the battery, identifying image regions where the comprehensive imaging image differs from the preset standard imaging image, and determining whether the battery is allowed to enter the subsequent production process based on the size of the image regions.

[0070] Optionally, determining whether to allow the battery to enter the subsequent production process based on the size of the image region includes: if the region size is greater than a preset safety region size, disallowing the battery from entering the subsequent production process and outputting a first detection result that the battery is a non-destructive battery; if the region size is less than or equal to the preset safety region size, allowing the battery to enter the subsequent production process and outputting a second detection result that the battery is a non-destructive battery.

[0071] In short, the detector integrates a defect identification module. This module communicates with the battery tooling platform in real time to acquire the target dimensions of the battery to be inspected. Based on the target dimensions, such as length, width, and thickness, it calls up a preset standard imaging image corresponding to that battery model. The preset standard imaging image is generated by statistical averaging and feature enhancement of a large number of qualified product imaging images, fully representing the normal distribution of the internal structure of the battery of this specification. Subsequently, the real-time acquired comprehensive imaging image is compared with the preset standard imaging image at the pixel level to accurately identify areas of difference in grayscale, edges, texture, or structure. The area of ​​the difference area is then calculated. The detection module receives this area data. If it exceeds the size of a preset safety area, it is determined to have an unacceptable defect, outputs the first detection result for a non-destructive battery, and triggers an interception signal to prevent the battery from entering the next process. If the area of ​​the difference area is less than or equal to the size of the preset safety area, the current battery is determined to meet the quality requirements, outputs the second detection result for a non-destructive battery, and allows the battery to continue to circulate.

[0072] Optionally, performing non-destructive testing on the battery based on the comprehensive imaging image further includes: mapping the multiple original projection images one-to-one with different sides of the battery, and obtaining side detection parameters configured for the non-destructive testing by the system management object; wherein the side detection parameters include at least: the number of sides and the type of sides; the number of sides is an integer greater than or equal to 2; selecting multiple target original projection images from the multiple original projection images based on the side detection parameters; and loading the multiple target original projection images onto the same interface for display.

[0073] Understandably, after acquiring multiple raw projection images, the detector establishes a one-to-one correspondence between each image and a specific side of the battery, filtering them according to the side detection parameters configured for the current non-destructive testing event in the system management object. These side detection parameters include at least the number of sides and the side type, where the number of sides is an integer greater than or equal to 2, and the side type is used to identify whether the corresponding side of the battery is a long side or a short side. Based on these side detection parameters, the detector selects multiple target images from all raw projection images that match the specified number and type of sides. For example, when the battery is quadrilateral, it has four sides, so four images corresponding to the four sides of the battery are selected. Then, these selected target raw projection images are uniformly loaded onto the same display interface for subsequent image registration and comprehensive analysis.

[0074] Optionally, for quadrilateral batteries, if 2 or 3 side detection parameters can meet production quality requirements, for the case of two sides, two long sides or two short sides of the battery, or two adjacent sides, can be selected. Then, the target original projection images corresponding to these sides can be selected, and the two target original projection images can be loaded onto the same display interface. For the case of three sides, three adjacent sides of the battery can be selected. If the battery is pentagonal, two adjacent sides and at least one of the remaining sides can also be selected. It should be noted that the above is merely an example and does not limit the battery shape of this application.

[0075] Optionally, the detection time of the battery is recorded, and if the detection time is longer than a preset detection time, the detection process of the battery is determined to be abnormal, and an alarm message is sent to the management object associated with the battery detection system; if the detection time is less than or equal to the preset detection time, the detection process of the battery is determined to be normal, and the number of batteries with normal detection processes that have been produced is counted.

[0076] Optionally, the battery testing system is also equipped with a testing control module and a testing statistics module to achieve comprehensive control of the testing process and battery production capacity recording. Specifically, the testing control module collects the entire testing time of each battery from loading and positioning to image acquisition completion in real time and compares it with the preset standard testing time. If the testing time exceeds the limit, such as due to abnormal X-ray source power, detector response delay, tooling positioning jamming, or increased friction of the moving mechanism, the testing process is immediately determined to be abnormal, and an alarm mechanism is automatically triggered to send maintenance alarm information containing equipment code, abnormal timestamp, timeout type, and possible fault source to production line managers and equipment maintenance personnel, realizing rapid response and preventive maintenance in the battery production process. Under the premise that the testing time meets the standard, the testing statistics module automatically includes the battery in the statistical pool of batteries that have passed the normal process, and accumulates the number of qualified batteries that have successfully completed non-destructive testing, providing data support for battery production capacity planning and quality traceability.

[0077] To better understand the process of the battery testing system and battery testing method described above, the implementation flow of the battery testing system and battery testing method will be further described below in conjunction with optional embodiments, but this is not intended to limit the technical solutions of the embodiments of this application.

[0078] This embodiment provides a management method for a battery testing system. Figure 3 This is a schematic diagram of the hardware structure of a battery detection system according to an embodiment of this application, such as... Figure 3As shown, it includes: a radiation source for irradiating the battery, a product platform for placing the battery, and a detector for collecting the radiation results. The radiation source employs a cone-beam projection. X-rays are emitted from the point-like radiation source, pass through the battery under inspection, and are imaged on the planar detector.

[0079] It should be noted that, Figure 4 This is a schematic diagram of the detection principle of a battery detection system according to an embodiment of this application. The X-ray source is a point light source, and the X-ray is emitted at a cone beam angle. The battery cell is penetrated by the X-ray. The battery cell has thickness, and a transition / blurred area d' is formed at the edge of the two-dimensional projected image. This transition / blurred area d' is caused by the image accumulation of the d region on the thickness h overlapping with the image of the object's edge. Furthermore, regarding the effective penetration thickness: for cylindrical or prismatic batteries, when the X-ray passes through its edge, the actual physical path of penetration is longer, and the equivalent thickness is greater, resulting in reduced image contrast, worse signal-to-noise ratio, and more difficult defect identification in this area. For example... Figure 4 Path 1 is located at the edge, so Path 1 has a longer actual physical path to penetrate than Path 2, and thus a greater equivalent thickness.

[0080] in, FDD is the distance between the X-ray source and the detector, h is the battery thickness, b is the length of the X-ray source shining on the side of the battery, α is the incident angle of the X-ray source, and FOD is the distance from the X-ray source to the object being measured. When b approaches ∞, the blind zone d” approaches 0; when α approaches 0 degrees, the blind zone d” approaches 0.

[0081] Therefore, it is clear that the theoretical size of region d' is affected by the following factors: (1) For the incident angle, the smaller the incident angle, the smaller the blind zone size; (2) The object thickness, the smaller the thickness, the smaller the blind zone size; Furthermore, the overall imaging effect of region d' is affected by the following factors: (1) Incident light intensity, the more photons emitted by the X-ray source, the better the image signal-to-noise ratio, and the more obvious the irradiated defects; (2) Incident light angle, that is, the smaller the angle, the more it tends to be perpendicular to the illumination, and the smaller its penetration path.

[0082] Optionally, the following solutions are proposed to reduce or eliminate the battery edge blind zone during the detection process.

[0083] Option 1 involves dividing the battery into two stations, imaging it using a two-stage projection method, with the tilt of the projection path and the field of view being the same in both stations. This reduces blind spots caused by physical factors and minimizes effective energy loss due to radiation attenuation over distance. However, the aforementioned transition / blurred area cannot be completely eliminated. Figure 5 This is a schematic diagram of the detection principle of bilateral irradiation according to an embodiment of this application.

[0084] Option 2, 3D CT, can perfectly overcome the fundamental problem. By rotating the battery 360°, hundreds or thousands of projected images are acquired from various angles, and then the complete 3D volume data is reconstructed by a computer. However, Option 2 will significantly increase costs and significantly decrease detection efficiency.

[0085] In summary, in order to better eliminate blind spots without increasing costs, we adopt Scheme 3.

[0086] Option 3: Eliminate blind spots. The object's center is aligned with the optical center. Since there are no blind spots in the center, but there are at the four edges, each edge is aligned with the optical center. Each shot places the edge area in the center of the field of view. Four shots are superimposed to cumulatively eliminate the blind spots (transition / blurred areas) at the four edges in the image. This is then applied to batteries. A four-station inspection of a single battery is performed, with the ray path of each station's ray source perpendicular to the edge of the blind spot. Each image is captured, eliminating the blind spot d' at the edge of the vertically aligned optical center. The battery edge is then placed in the center of the field of view, with the ray closely following the battery edge and illuminating vertically. The ray path and the incident angle with the side of the battery are 0, completely avoiding the generation of the original blind spot d' at this edge. Figure 6 This is a schematic diagram of a four-position battery detection according to an embodiment of this application. Specifically, the center of each side of the battery (side 1, side 2, side 3, and side 4) is aligned with the optical center.

[0087] Optional, Figure 7 This is a schematic diagram of the multi-sided illumination detection principle according to an embodiment of this application. The edge region that would normally generate an imaging blind zone is placed at the center of the field of view. Previously, the projection path of this region was tilted; after being placed at the center, the projection path becomes more vertical, resulting in minimal image distortion and the highest resolution. Furthermore, the incident angle decreases, eliminating the blind zone while simultaneously reducing the penetration path in that region. This improves the image signal-to-noise ratio of the previously blind zone area, making defects more apparent. However, the opposite edge still has the longest penetration path, meaning that while one angle provides the best field of view, it is precisely the other angle provides the worst.

[0088] For example, using a four-station inspection, four images are taken, each aligning the optical center of the ray with one of the four edges of the battery, and the information is stitched together. The imaging application automatically aligns the four images, performs contrast optimization and feature enhancement, and displays the image information from the four images on the same screen.

[0089] In summary, by fixing the battery with tooling and positioning it according to the battery size parameters, the battery is held in place by a station fixture and rotated / translated. Conical X-ray images are then taken along the four edges to eliminate blind spots in non-destructive testing. This means that by taking images of the four sides from four different stations, the previously blurred areas at the four edges under a single viewpoint are transformed into four clear central field-of-view images, meeting the requirements for large-area non-destructive testing of batteries. Furthermore, the four-station rotation or assembly line design enables automatic battery loading, positioning, imaging, and unloading, improving the battery testing cycle time and facilitating automated testing on battery production lines. In addition, compared to CT, the above multi-angle battery testing system has lower equipment costs and scanning time, ensuring efficiency while minimizing cost, making it suitable for large-scale application.

[0090] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods according to the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal device (which may be a mobile phone, computer, server, or network device, etc.) to execute the methods of the various embodiments of this application.

[0091] Embodiments of this application also provide a storage medium including a stored program, wherein the program executes any of the methods described above when it is run.

[0092] Optionally, in this embodiment, the storage medium may be configured to store program code for performing the following steps:

[0093] S1, when at least one battery side of the battery is aligned with the optical center of the X-ray source device, control the X-ray source device to vertically irradiate the at least one battery side through the X-ray source, and instruct the detector connected to the X-ray source device to collect X-ray imaging data of the at least one battery side.

[0094] S2, Based on the ray imaging data, determine the original projection image of the at least one battery side, and determine the comprehensive imaging image corresponding to the battery according to the multiple original projection images corresponding to the multiple battery sides on the battery;

[0095] S3, perform non-destructive testing on the battery based on the comprehensive imaging image.

[0096] Embodiments of this application also provide an electronic device including a memory and a processor, wherein the memory stores a computer program and the processor is configured to run the computer program to perform the steps in any of the above method embodiments.

[0097] Optionally, the electronic device may further include a transmission device and an input / output device, wherein the transmission device is connected to the processor and the input / output device is connected to the processor.

[0098] Optionally, in this embodiment, the processor can be configured to perform the following steps via a computer program:

[0099] S1, when at least one battery side of the battery is aligned with the optical center of the X-ray source device, control the X-ray source device to vertically irradiate the at least one battery side through the X-ray source, and instruct the detector connected to the X-ray source device to collect X-ray imaging data of the at least one battery side.

[0100] S2, Based on the ray imaging data, determine the original projection image of the at least one battery side, and determine the comprehensive imaging image corresponding to the battery according to the multiple original projection images corresponding to the multiple battery sides on the battery;

[0101] S3, perform non-destructive testing on the battery based on the comprehensive imaging image.

[0102] Optionally, in this embodiment, the storage medium may include, but is not limited to, various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0103] Optionally, embodiments of this application also provide a computer program product, which includes a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0104] Optionally, embodiments of this application also provide another computer program product, including a non-volatile computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps in any of the above method embodiments.

[0105] Optionally, embodiments of this application also provide a computer program that includes computer instructions stored in a computer-readable storage medium; a processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the steps in any of the above method embodiments.

[0106] Optionally, specific examples in this embodiment can refer to the examples described in the above embodiments and optional implementations, and will not be repeated here.

[0107] Obviously, those skilled in the art should understand that the modules or steps of this application described above can be implemented using general-purpose computing devices. They can be centralized on a single computing device or distributed across a network of multiple computing devices. Optionally, they can be implemented using computer-executable program code, thereby storing them in a storage device for execution by a computing device. In some cases, the steps shown or described can be performed in a different order than those presented here, or they can be fabricated as separate integrated circuits, or multiple modules or steps can be fabricated as a single integrated circuit. Thus, this application is not limited to any particular hardware and software combination.

[0108] The above are merely preferred embodiments of this application. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A battery testing system, characterized in that, include: A radiation source device, and a detector connected to the radiation source device; The radiation source device is used to vertically irradiate at least one side of the battery when the radiation source device's radiation optical center is aligned with at least one battery side of the battery, so as to perform radiation imaging on the battery. The detector is used to acquire X-ray imaging data of the side of at least one battery, generate an original projection image of the side of at least one battery based on the X-ray imaging data, and determine a comprehensive imaging map of the battery based on multiple original projection images corresponding to multiple battery sides on the battery. The comprehensive imaging map is used for non-destructive testing of the battery.

2. The battery testing system according to claim 1, characterized in that, The battery testing system also includes: a battery tooling platform; The battery fixture platform is used to fix the battery and determine the battery detection trajectory corresponding to the target size of the battery and the operating parameters of the X-ray source device, wherein the target size includes at least one of the following: the length of the battery, the width of the battery, and the thickness of the battery.

3. The battery testing system according to claim 2, characterized in that, The battery tooling platform also includes: A turntable at the workstation is used to control the rotation of the battery at different angles; A clamping mechanism, installed on the workstation turntable, is used to secure the battery and perform planar translation and angle correction on the battery.

4. The battery testing system according to claim 2, characterized in that, The battery tooling platform also includes: The parameter preset module is used to store the association between the reference dimensions of multiple types of batteries and multiple reference trajectories corresponding to the battery tooling platform; The calling module, connected to the parameter preset module, is used to determine the current detection trajectory to be executed by the battery tooling platform based on the target size, and to determine the operating parameters of the X-ray source device corresponding to the detection trajectory, wherein the detection trajectory is used to indicate the rotation angle of the battery tooling platform; The platform communication module is connected to the radiation source device and is used to synchronize the operating parameters to the radiation source device.

5. The battery testing system according to claim 1, characterized in that, The detector also includes: The defect identification module is connected to the battery tooling platform and is used to determine the preset standard imaging image to be called according to the target size of the battery, identify the image area where the comprehensive imaging image differs from the preset standard imaging image, and determine whether the battery is allowed to enter the subsequent production process based on the size of the image area.

6. The battery testing system according to claim 5, characterized in that, The detector also includes: The detection module, connected to the defect identification module, is used to prevent the battery from entering the subsequent production process and output a first detection result indicating that the battery is a non-destructive battery if the area size is larger than the preset safety area size; and to allow the battery to enter the subsequent production process and output a second detection result indicating that the battery is a non-destructive battery if the area size is smaller than or equal to the preset safety area size.

7. The battery testing system according to claim 1, characterized in that, The detector is also used to map the multiple original projected images to different sides of the battery one by one, and to obtain the side detection parameters configured for the non-destructive testing by the system management object; wherein, the side detection parameters include at least: the number of sides and the type of sides; the number of sides is an integer greater than or equal to 2; Multiple target original projection images are selected from the multiple original projection images based on the side detection parameters; The original projected images of the multiple targets are loaded and displayed on the same interface.

8. The battery testing system according to claim 7, characterized in that, The detector also includes: The image registration module is used to spatially align the multiple original projection images of the targets based on a preset image registration algorithm before loading and displaying them on the same interface, thereby obtaining multiple aligned images; and input the multiple aligned images into a trained local deformation compensation model to generate multiple images to be fused.

9. The battery testing system according to claim 8, characterized in that, The detector also includes: An image fusion module, connected to the image registration module, is used to perform fusion processing on the multiple images to be fused to generate a comprehensive imaging image. The comprehensive imaging image is obtained by selecting the target side corresponding to the original projection image of the target on the side distribution diagram corresponding to the battery, and filling the side distribution diagram with the image to be fused corresponding to the original projection image of the target.

10. The battery testing system according to claim 1, characterized in that, The battery testing system also includes: The detection control module is used to record the detection time of the battery, and if the detection time exceeds the preset detection time, it determines that the detection process of the battery is abnormal and sends an alarm message to the management object associated with the battery detection system. The detection statistics module is used to determine that the detection process of the battery is normal when the detection time is less than or equal to the preset detection time, and to count the number of batteries that have been produced with normal detection process.

11. A battery testing method applied to the battery testing system of any one of claims 1 to 10, characterized in that, include: When at least one side of the battery is aligned with the optical center of the X-ray source device, the X-ray source device is controlled to vertically irradiate the at least one side of the battery through the X-ray source, and the detector connected to the X-ray source device is instructed to collect X-ray imaging data of the at least one side of the battery. Based on the X-ray imaging data, the original projection image of the side of at least one battery is determined, and the comprehensive imaging image corresponding to the battery is determined based on the multiple original projection images corresponding to the multiple battery sides on the battery. The battery is subjected to non-destructive testing based on the comprehensive imaging image.

12. A single-cell battery, the single-cell battery comprising a non-destructive battery, the non-destructive battery being a battery that is determined to be free of defects after being subjected to radiographic testing using the battery testing system of any one of claims 1 to 10.

13. A battery pack, characterized in that, It includes at least two individual cells as described in claim 12, and each of the individual cells is electrically connected to the other.

14. A battery pack, characterized in that, It includes a housing and at least two battery packs as described in claim 13, each of the battery packs being disposed within the housing and electrically connected to each other.

15. An electric vehicle, characterized in that, It includes at least the battery pack as described in claim 14.

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