Tab alignment detection cutting processing method, electronic device, and storage medium

Abstract

This invention discloses a method for detecting and cutting tab alignment, an electronic device, and a storage medium. The method includes: processing continuous images of the tab stacking area to be processed in real time to determine the tab misalignment region and identify the boundary of each tab layer; detecting the tabs in the misalignment region by distance measurement to determine the deviation measurement value between the tabs; calculating preset misalignment parameters using a preset calculation model based on the measurement value; and controlling the device to output cutting parameters for alignment cutting according to preset welding quality targets based on the preset misalignment parameters. This invention enables real-time, high-precision online detection of misalignment information of stacked tabs in front of the welding position during cell production, and dynamically adjusting laser welding parameters based on the detection results, fundamentally improving problems or defects such as difficulty in tab alignment, poor product consistency, and serious electrode waste during production and testing.

Description

Technical Field

[0001] This invention relates to the field of lithium battery tab alignment processing technology, and in particular to a tab alignment detection and cutting processing method, electronic device and storage medium. Background Technology

[0002] In the mass production of pouch lithium batteries and square aluminum-cased batteries, multiple electrode sheets with exposed current collector tabs need to be stacked and then welded together to form the current lead of the battery cell. On actual automated production lines, due to a combination of factors such as insufficient electrode cutting precision, stacking positioning drift, equipment vibration, and electrode deformation, multi-layer tabs commonly exhibit interlayer misalignment and uneven edges after stacking. The flatness of the tabs fails to meet process requirements, becoming a significant factor restricting welding quality.

[0003] To meet the design goals of low center of gravity, high stability, and high comfort in vehicles, power batteries are continuously being upgraded towards higher energy density and higher volumetric energy density. This leads to a constant reduction in redundancy within the cell's internal structure, resulting in very tight assembly margins. To accommodate dimensional deviations caused by misaligned tabs, manufacturers typically have to passively compress the assembly space in the cell's height and thickness. This practice easily causes deformation of the electrode sheets under pressure, not only weakening the cell's safety performance but also exacerbating the expansion phenomenon at the end of the cell's lifespan, directly affecting the cell's cycle life and long-term reliability.

[0004] At the same time, the misalignment of the electrode tabs can significantly disrupt the uniformity of the welding area, leading to uneven distribution of laser welding energy, which in turn causes problems such as incomplete welding, over-welding, and electrode tab tearing. Under conditions such as vehicle vibration, high and low temperature changes, and high-rate charging and discharging, there are safety hazards such as poor contact and local overheating.

[0005] Currently, electrode alignment is often improved by adjusting the electrode thickness ratio or by embossing the electrodes. However, these methods have limited adjustment range and cannot systematically solve production line deviation problems. More importantly, the embossing process damages the surface morphology and structural integrity of the electrodes, affecting the adhesion stability of active materials and the internal stress distribution of the cell. This is detrimental to the consistent control of cell performance and cannot meet the manufacturing requirements of high-end power batteries.

[0006] The core demands of the current new energy vehicle market for battery cells have become the main direction for manufacturers' technological research and development and performance upgrades. On the one hand, battery cells are required to have excellent safety performance, ensuring that vehicles are free from thermal runaway, fire, and other safety risks during the entire life cycle of charging and discharging and under complex operating conditions. On the other hand, battery cells need to have high manufacturing consistency between batches and individual cells, mitigating the "weakest link" effect and reducing performance losses and system bottlenecks caused by uneven internal resistance and capacity dispersion. At the same time, cost optimization is needed through improving the level of refined manufacturing, reducing the reliance on structural redundancy and design margins to passively compensate for insufficient manufacturing precision, thereby improving reliability while reducing overall manufacturing costs. Therefore, it is necessary to propose new technologies to improve the welding quality problem caused by the misalignment of the electrode tabs. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings and defects of existing technologies and provide a method for detecting and cutting electrode alignment, an electronic device, and a storage medium. This invention uses the actual misalignment state information of the electrode as input and laser welding parameters as output to form a continuous closed-loop control, thereby ensuring welding consistency and electrode integrity on high-speed power battery mass production lines.

[0008] The first aspect of the present invention provides a method for detecting and cutting electrode alignment, comprising the steps of:

[0009] Continuous image processing of the real-time acquired electrode stacking area to determine the electrode misalignment region and identify the boundary of each electrode layer;

[0010] In the electrode misalignment region, the deviation between electrodes is determined by distance measurement.

[0011] Based on the measured values, a preset misalignment parameter is calculated using a preset calculation model. Based on the preset misalignment parameter, the control equipment outputs cutting parameters to align the cutting according to the preset welding quality target.

[0012] Preferably, the deviation measurement value is decomposed into two preset parameters, a fixed misalignment amount ΔL and an incremental misalignment amount Δ&, by a preset calculation model; the incremental misalignment amount Δ& is the incremental deviation caused by the difference between the measured thickness and the calculated thickness.

[0013] Preferably, before acquiring continuous images of the electrode stacking area in real time, a step of pre-flattening the stacked electrodes is also included.

[0014] Preferably, the electrode misalignment region and the position of each electrode layer are detected and determined using edge detection and region segmentation algorithms.

[0015] As a preferred method, non-contact laser testing technology is used to measure the distance of the electrodes in the electrode misalignment area.

[0016] Preferably, the cutting parameters are laser cutting parameters, including at least welding speed, pulse width, pulse peak power, pulse frequency, and defocusing amount.

[0017] Preferably, the electrode stacking area has a protruding structure and / or a recessed structure on the side of the electrode stack away from the electrode assembly body, for the detection positioning, tracking and deviation measurement positioning of the vision inspection module.

[0018] In a second aspect, the present invention provides an electronic device comprising: a memory for storing computer-executable instructions or computer programs; and a processor for executing the computer-executable instructions or computer programs stored in the memory to implement the tab alignment detection and cutting processing method.

[0019] A third aspect of the present invention provides a computer-readable storage medium storing computer-executable instructions or a computer program, wherein when the computer-executable instructions or the computer program are executed by a processor, the tab alignment detection and cutting processing method described above is implemented.

[0020] The technology of this invention enables real-time, high-precision online detection of misalignment information of stacked tabs in front of the welding position during the cell production process, and dynamically adjusts laser welding parameters based on the detection results, fundamentally improving problems or defects such as difficulty in tab alignment, poor product consistency, and serious electrode waste during production and testing. Attached Figure Description

[0021] Figure 1 This is a flowchart of the electrode alignment detection and cutting process method of the present invention.

[0022] Figure 2 This is a schematic diagram of a cell electrode assembly without tabs or misaligned layers.

[0023] Figure 3 This is a schematic diagram of a battery cell with staggered tabs.

[0024] Figure 4 This is a schematic diagram showing the distance between misaligned tabs in a battery cell with misaligned tabs. Detailed Implementation

[0025] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0026] See Figure 1 As shown, an embodiment of this application provides a method for detecting and cutting the tab alignment, including the following steps:

[0027] S1. Process the continuous images of the electrode stacking area to be processed acquired in real time, determine the electrode misalignment area and identify the boundary of each electrode layer;

[0028] S2. For the electrode ears in the misaligned region, the deviation measurement value between the electrodes is determined by distance measurement;

[0029] S3. Calculate the preset misalignment parameters using the preset calculation model based on the measured values. Based on the preset misalignment parameters, control the equipment to output cutting parameters for alignment cutting according to the preset welding quality target.

[0030] The technology of this invention does not rely on mechanical structure correction during the winding stage, nor does it depend on hardware actuators for compensation, nor is it limited to simple detection. Instead, it revolves around a full-process intelligent control mode of online sensing—real-time calculation—dynamic execution—closed-loop iteration, overcoming the lag defects of traditional offline debugging and manual correction, and achieving real-time response and autonomous optimization of electrode misalignment deviation. After the electrode is detected to have a misaligned layer, the welding parameters are optimized in real time in the winding direction around the entire electrode assembly through algorithms, realizing integrated linkage correction of detection and control, thereby forming a closed-loop adaptive control that is more suitable for actual production.

[0031] The preset misalignment parameters consist of a fixed misalignment amount ΔL and an incremental misalignment amount Δ&, where the incremental misalignment amount Δ& is the incremental deviation caused by the difference between the measured thickness and the calculated thickness. Using a preset calculation model, based on the measured deviation between the tabs, the fixed misalignment amount ΔL and the incremental misalignment amount Δ& are calculated to control the operating parameters of the cutting equipment, thereby achieving laser cutting.

[0032] In a specific implementation, to further improve detection accuracy and welding stability, a pre-flattening step is included before acquiring continuous images of the electrode stacking area in real time during production. Specifically, this can be achieved by setting a longitudinal precision flattening mechanism at the front end of the electrode detection station. This mechanism can use flexible pressure rollers and constant force control to pre-flatten and level the stacked electrodes without damaging the electrode surface and active material, eliminating electrode warping, floating, and lateral displacement, ensuring consistent electrode posture in the conveyor belt direction, thereby significantly improving the reliability of misalignment detection and laser welding.

[0033] In a specific implementation, the misaligned electrode layer region and the position of each electrode layer are detected and determined using edge detection and region segmentation algorithms. This can be determined by a visual inspection mechanism embedded with the algorithm, such as using a high frame rate linear array camera to continuously acquire images of the electrode stacking region. By combining edge detection and region segmentation algorithms, the contour of the misaligned electrode layer region can be accurately identified, and the first layer edge, middle layer position, and last layer boundary of the electrode in the misaligned layer region can be automatically located, providing a positional reference for subsequent quantization calculations.

[0034] In specific implementation, for example, non-contact laser testing technology can be used to measure and detect the gap, height difference, and misalignment deviation in the tab misalignment area. Of course, other non-contact ranging technologies can also be used, not limited to these. For example, after visual positioning is completed, an infrared laser sensor can be used to perform non-contact ranging on the calibrated misalignment area to obtain the actual gap, height difference, and misalignment deviation between the tabs of each layer, converting the analog quantities into digital deviation signals to provide reliable data support for subsequent decision-making.

[0035] The aforementioned non-contact ranging and staggered area positioning equipment constitute the real-time detection module of this application, which performs the system's sensing function and can stably perform imaging and high-precision ranging processing under high-speed conveyor belt conditions.

[0036] In one specific implementation, a laser cutting device is used for the alignment cutting of the tabs. For example, the cutting parameters are laser cutting parameters, including at least welding speed, pulse width, pulse peak power, pulse frequency, and defocusing amount. During laser cutting, based on a preset target quality and the detected tab misalignment, such as misalignment information, laser cutting is performed to ensure that the aligned tabs meet the preset alignment requirements after laser cutting.

[0037] In this application, an intelligent decision-making module is set up for data processing. For example, after receiving the detection data, it is set up to comprehensively calculate the electrode misalignment amount, thickness fluctuation and tape speed through the built-in algorithm model, generate the optimal laser output parameters in real time according to the preset welding quality target, and dynamically adjust key indicators such as pulse width, peak power, welding speed and defocusing amount for laser cutting.

[0038] The intelligent decision-making module is based on a high-performance embedded processor or industrial computer, equipped with adaptive algorithms and deep learning models. It has the capabilities of data parsing, logical operation, parameter optimization and self-learning iteration. It has adaptive learning and online optimization capabilities, and can continuously accumulate working condition data during continuous production to gradually optimize the control model. It can achieve short-term rapid closed-loop and long-term continuous iterative control effects, so that the system can maintain stable and reliable compensation capabilities under the interference of material fluctuations, equipment wear and tear, and environmental changes.

[0039] In actual high-speed production processes, tabs often have problems such as small layer misalignment, mutual occlusion between layers, and unclear edge contours, which can easily lead to misjudgment, missed detection, or recognition delay in visual inspection.

[0040] To facilitate the positioning and detection of stacked tabs by visual inspection agencies, effectively avoid the aforementioned problems, improve the recognition efficiency and positioning accuracy of the visual system, and ensure that the entire detection and control system can respond stably and promptly, this invention provides a structurally reinforced design for the tab ends. That is, the tab structure itself is specially and adaptably designed to facilitate online detection and recognition. For example, the top of the tab 1 of the tab group 100 is provided with a distinct outward convex feature, making it easier for the visual inspection agency to capture and track it. For example, in this application, a protruding structure and / or a recessed structure are provided on the side of the tab away from the tab group body in the tab stacking area for detection positioning, tracking, and deviation measurement positioning of the visual inspection module. The protruding structure is such as a triangular protruding structure 2.

[0041] In this embodiment, a triangular protruding structure is preferred. This structure has a clear outline and prominent corner features, which can maintain stable algorithm recognition performance even in complex lighting and motion blur scenarios. Specifically, the recognition structure can also be flexibly adjusted to various forms such as trapezoidal, semi-circular, and notched positioning features to accommodate the detection habits of different production line equipment, depending on the vision solutions, light source types, image algorithms, and detection accuracy requirements of different manufacturers.

[0042] In the pre-calculation model of this application, the misalignment amount of the electrode cut by laser cutting is divided into a fixed misalignment amount ΔL and an incremental misalignment amount Δ& caused by the deviation of the increment due to the difference between the actual thickness and the calculated thickness. These together constitute the absolute misalignment amount L. For example, ΔL + Δ& = L1, 2ΔL + 3Δ& = L2, 3ΔL + 6Δ& = L3, 4ΔL + 10Δ& = L4, 5ΔL + 15Δ& = L5, and so on. When the number of electrodes is even, 1 / 2nΔL + 1 / 2*n / 2*(n / 2+1)Δ& = L(n / 2); when the number of electrodes is odd, 1 / 2(n+1)ΔL + 1 / 2(n / 2+1 / 2)(n / 2+3 / 2), nΔL + n(n+1)Δ& = Ln. Wherein, L1, L2, L3, and L4 are the offset distances between the first tab and the middle tab, and between the middle tab and the terminal tab, respectively, of the tabs of the positive and negative electrodes. Figure 4 To increase the accuracy of calculation and measurement, since the larger the distance between the electrodes, the smaller the measurement error and the lower the corresponding requirements of the machine, the distance between the nth electrode and one electrode and the distance between the nth electrode and the 1 / 2n or 1 / 2(n+1)th electrode are used as input parameters to calculate the laser cutting correction amount.

[0043] When n is even: (n-1)△L + (1 / 2n² + 1 / 2n - 1 / 2)△& = △Ln - △L1; 1 / 2n△L + (3 / 8n² + 1 / 4n)△& = △Ln - △Ln / 2;

[0044] When n is odd; (n-1)△L+(1 / 2n²+1 / 2n-1 / 2)△&=△Ln-△L1; 1 / 2(n-1) △L+(3 / 8n²-3 / 8) △&=△Ln-△L(n+1) / 2;

[0045] Wherein, △Ln-△L1 represents the distance between the nth electrode and the first electrode; △Ln-△Ln / 2 represents the distance between the nth electrode and the n / 2nd electrode; △Ln-△L(n+1) / 2 represents the distance between the nth electrode and the (n+1) / 2nd electrode; △Ln-△L1, △Ln-△Ln / 2, and △Ln-△L(n+1) / 2 are all measured values, used as input values ​​for calculation, to calculate △L and △&, which are used as input parameters for controlling the laser cutting device.

[0046] In this application, the electrode misalignment detection and laser cutting correction are all completed by a computing center. The computing center stores preset algorithm software, analyzes the collected data values, comprehensively evaluates the state of the electrode ears, and determines the adjustment scheme for subsequent laser welding, thereby realizing the technology of this invention.

[0047] In a further embodiment of this application, an electronic device is provided, comprising: a memory for storing computer-executable instructions or computer programs; and a processor for executing the computer-executable instructions or computer programs stored in the memory to implement the tab alignment detection and cutting processing method.

[0048] A further embodiment of this invention provides a computer-readable storage medium storing computer-executable instructions or a computer program, wherein when the computer-executable instructions or the computer program are executed by a processor, the tab alignment detection and cutting processing method is implemented.

[0049] This invention enables continuous, uninterrupted production line operation, simultaneously monitoring electrode thickness and tab misalignment in real time during operation, and autonomously optimizing laser welding parameters based on the current actual state of the electrode assembly. Compared to the traditional method of manually setting and correcting parameters, it achieves fully automated calculation and real-time dynamic adjustment, establishing a complete closed-loop control system and significantly improving production efficiency and process stability.

[0050] By comprehensively controlling various factors that cause electrode alignment deviations, the electrode misalignment can be effectively kept at an extremely low level, significantly reducing electrode wear and material waste. Simultaneously, no modification treatments such as embossing are required for the electrodes, avoiding structural damage. This allows for fully ensuring the original performance of the battery cell and product consistency in an automated production environment without human intervention.

[0051] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects. The scope of the present invention is defined by the appended claims rather than the foregoing description, and therefore all changes falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention.

[0052] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A method for detecting and cutting electrode alignment, characterized in that, Including the following steps: Continuous image processing of the real-time acquired electrode stacking area to determine the electrode misalignment region and identify the boundary of each electrode layer; In the electrode misalignment region, the deviation between electrodes is determined by distance measurement. Based on the measured values, a preset misalignment parameter is calculated using a preset calculation model. Based on the preset misalignment parameter, the control equipment outputs cutting parameters to align the cutting according to the preset welding quality target.

2. The electrode alignment detection and cutting processing method according to claim 1, characterized in that, The deviation measurement value is decomposed into two preset parameters, a fixed misalignment amount △L and an incremental misalignment amount △&, by a preset calculation model; the incremental misalignment amount △& is the incremental deviation caused by the difference between the measured thickness and the calculated thickness.

3. The electrode alignment detection and cutting method according to claim 1, characterized in that, Before acquiring continuous images of the electrode stacking area in real time, the process also includes a step of pre-flattening the stacked electrodes.

4. The electrode alignment detection and cutting method according to claim 1, characterized in that, The electrode layer misalignment region and the position of each electrode layer are determined by edge detection and region segmentation algorithms.

5. The electrode alignment detection and cutting processing method according to claim 1, characterized in that, Non-contact ranging technology is used to measure and detect the electrodes in the electrode misalignment area.

6. The electrode alignment detection and cutting processing method according to claim 5, characterized in that, Non-contact laser ranging technology is used to measure and detect the electrodes in the electrode misalignment area.

7. The electrode alignment detection and cutting processing method according to claim 1, characterized in that, The cutting parameters are laser cutting parameters, including at least welding speed, pulse width, pulse peak power, pulse frequency, and defocusing amount.

8. The electrode alignment detection and cutting processing method according to claim 1, characterized in that, The electrode stacking area has protruding and / or recessed structures on the sides of the electrode stack away from the electrode assembly body, which are used for the detection, positioning, tracking, and measurement of deviation by the vision inspection module.

9. An electronic device, characterized in that, The electronic device includes: a memory for storing computer-executable instructions or computer programs; and a processor for executing the computer-executable instructions or computer programs stored in the memory to implement the tab alignment detection and cutting processing method according to any one of claims 1 to 8.

10. A computer-readable storage medium storing computer-executable instructions or a computer program, characterized in that, When the computer-executable instructions or computer program are executed by the processor, the tab alignment detection and cutting processing method according to any one of claims 1 to 8 is implemented.

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