A new energy automobile battery module appearance defect automatic sorting device

Abstract

The application discloses a new energy automobile battery module appearance defect automatic sorting device, including main frame, conveying module, clamping assembly, visual detection assembly, sorting push rod and control system. The conveying module is composed of a first and a second conveying belt which are parallel and adjacent in opposite conveying directions. The clamping assembly spans the two conveying belts and can automatically transfer the battery module from the first conveying belt to the second conveying belt. The visual detection assembly uses an adjustable height industrial camera and an isolation lifting plate to accurately position and image collect the battery module on the second conveying belt. The sorting push rod automatically pushes out the unqualified product according to the visual detection result. The utility model realizes the full process automation of battery module feeding, transfer, detection and sorting, has the advantages of compact layout, accurate detection, high sorting efficiency and strong adaptability, and effectively improves the product quality and production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation and quality inspection technology, and in particular to an automatic sorting device for appearance defects in new energy vehicle battery modules. Background Technology

[0002] The power battery is a core component of new energy vehicles, and the appearance quality of its modules (such as scratches, dents, bulges, contamination, and damage to polarity terminals) directly affects the overall safety and reliability of the battery pack. Currently, many battery manufacturers in China still mainly rely on manual visual inspection to examine the appearance of battery modules. This method has the following significant drawbacks: Inefficient and costly: Manual inspection is slow and difficult to match the production rhythm of automated production lines. It also requires a large number of skilled quality inspectors, resulting in high labor and management costs.

[0003] While some attempts have been made to adopt automated vision inspection solutions, these typically suffer from issues such as low system integration, poor coordination between inspection and sorting stations, and limited adaptability to different battery module models. For example, using a single conveyor belt for both feeding and inspection can easily lead to process interference; or the sorting mechanism may be complex, affecting overall efficiency and reliability. Therefore, there is an urgent need for a compact, accurate, efficient, and flexible automated sorting device. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automatic sorting device for appearance defects of new energy vehicle battery modules with a reasonable layout, high degree of automation, and smooth detection and sorting process.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: including: Mainframe rack; The conveying module is mounted on the main frame. The conveying module includes a primary conveyor belt for feeding and a secondary conveyor belt for detection. The primary conveyor belt and the secondary conveyor belt are adjacent to each other and parallel to each other, and their conveying directions are opposite. A clamping assembly is disposed above the primary conveyor belt and the secondary conveyor belt, for transferring the battery module from the primary conveyor belt to the secondary conveyor belt; A visual inspection component is disposed above the secondary conveyor belt and is used to inspect the appearance defects of the battery module. The sorting pusher is located on one side of the secondary conveyor belt next to the vision inspection component, and is used to push out the battery modules that fail the inspection. The system is electrically connected to the conveying module, clamping assembly, vision inspection assembly, and sorting push rod.

[0006] Preferably, the clamping assembly includes an upper fixing plate, a mating slide rail, a drive block, and a battery clamping plate; the upper fixing plate is horizontally disposed above the primary conveyor belt and the secondary conveyor belt, the mating slide rail is disposed on the upper fixing plate, the drive block is slidably engaged with the mating slide rail, and the battery clamping plate is connected below the drive block.

[0007] Preferably, the vision inspection component includes a position adjustment frame, an industrial camera, and an isolation lifting plate; the position adjustment frame is positioned above the secondary conveyor belt, the industrial camera is adjusted in height via the position adjustment frame, and the isolation lifting plate is positioned next to the industrial camera for isolating and positioning the battery module during inspection.

[0008] Preferably, the industrial camera includes an internal camera support, a ring light source, and a detection lens; the ring light source is mounted on the bottom edge of the internal camera support, and the detection lens is located at the center of the ring light source.

[0009] Preferably, the device further includes a display panel and a storage cabinet; the display panel is mounted on the main frame and connected to the control system, and the storage cabinet is located inside the main frame.

[0010] Preferably, the primary conveyor belt and the secondary conveyor belt are at the same height.

[0011] Preferably, the industrial camera is vertically aligned with the secondary conveyor belt.

[0012] Preferably, the sorting push rod is a pneumatic push rod or an electric push rod, and its action is controlled by the control system based on the detection results of the vision inspection component.

[0013] Preferably, the control system is configured to: receive image data from the vision inspection component and perform defect analysis; if the defect is determined to be unqualified, control the sorting push rod to start when the battery module arrives at the sorting station and push it away from the secondary conveyor belt.

[0014] Preferably, the primary conveyor belt and the secondary conveyor belt are each driven by an independent drive motor.

[0015] Compared with the prior art, this utility model provides an automatic sorting device for appearance defects in new energy vehicle battery modules, which has the following beneficial effects: 1. The device adopts a highly efficient assembly line layout and uses a dual conveyor belt design with opposite conveying directions inside, which realizes the physical separation and logical connection of the feeding and testing areas. With the help of clamping components, it realizes automatic transfer, smooth process, short cycle time and high efficiency.

[0016] 2. The device's internal vision inspection components integrate an adjustable-height industrial camera, a dedicated ring light source, and an isolation positioning mechanism, ensuring high-quality and repeatable image acquisition and greatly improving the accuracy and reliability of the inspection. At the same time, it adopts rapid sorting, with the sorting push rod acting directly according to system commands, responding quickly and performing the sorting action crisply and cleanly, seamlessly integrating with the conveying process. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a structural schematic diagram of a specific embodiment of the present utility model; Figure 2 This is a partial enlarged view of point A in this utility model; Figure 3 This is a schematic diagram of the clamping component in a specific embodiment of the present invention; Figure 4 This is a schematic diagram of the detection structure of the industrial camera in a specific embodiment of this utility model.

[0018] In the diagram: 1. Main frame; 2. Primary conveyor belt; 3. Secondary conveyor belt; 4. Display panel; 5. Clamping assembly; 6. Vision inspection assembly; 7. Sorting push rod; 11. Storage cabinet; 101. Upper fixing plate; 102. Matching slide rail; 103. Drive block; 104. Battery clamping plate; 201. Position adjustment frame; 202. Industrial camera; 203. Isolation lifting plate; 301. Camera inner bracket; 302. Ring light source; 303. Inspection lens. Detailed Implementation

[0019] To more clearly illustrate the overall concept of this application, a detailed explanation is provided below with reference to the accompanying drawings.

[0020] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0021] Furthermore, it should be understood in the description of this application that the terms "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0022] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0023] In this application, unless otherwise expressly specified and limited, the "above" or "below" of the second feature can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples.

[0024] Example 1: like Figure 1-4 As shown, this utility model provides an automatic sorting device for appearance defects in new energy vehicle battery modules. Its main body is a rigid main frame 1 constructed from welded or bolted profiles. This main frame 1 provides a stable support foundation for the entire device. On the upper platform of the main frame 1, a primary conveyor belt 2 and a secondary conveyor belt 3, constituting the conveying module, are installed. Both conveyor belts adopt the same structure, consisting of a drive motor, rollers, and conveyor belts, and are installed at the same horizontal height, arranged adjacent to each other in parallel. Its core feature is that the primary conveyor belt 2 conveys towards the inside of the device as the loading section, while the secondary conveyor belt 3 conveys in the opposite direction, serving as the detection and sorting section. This layout clearly divides the functional areas. A display panel 4 is installed on the side of the main frame 1 at an easily observable location to display real-time information such as detection results, system status, and production statistics. The internal space of the main frame 1 is rationally utilized, with storage cabinets 11 provided for storing electrical components such as industrial control computers and PLCs, or maintenance tools in the control system.

[0025] The clamping assembly 5 is a key component in the entire device for achieving automatic material transfer. For example... Figure 1 and Figure 2As shown, it is fixed above the primary conveyor belt 2 and the secondary conveyor belt 3 via an upper fixing plate 101. Two parallel mating slide rails 102 are fixedly installed on the upper fixing plate 101. A drive block 103 forms a sliding engagement with the mating slide rails 102 via a linear slider. This drive block 103 is driven by a horizontally mounted cylinder and can move precisely and smoothly laterally along the slide rails. Below the drive block 103, a battery clamping plate 104 is bolted to it. In this embodiment, the battery clamping plate 104 can be designed as a gripper mechanism with flexible padding, or a simple "L"-shaped support plate, depending on the shape of the battery module, with the aim of reliably transferring the battery module without causing surface damage.

[0026] The visual inspection component 6 is the core component that ensures inspection accuracy. For example... Figure 1 and Figure 3 As shown, a position adjustment frame 201 is securely mounted on a frame or foundation next to the secondary conveyor belt 3 by bolts. This position adjustment frame 201 can be a manually adjustable lead screw slide module or an automatic lifting module driven by a servo motor. Its function is to support the industrial camera 202 and allow the operator to finely adjust the focal length and working distance of the industrial camera 202 according to the height of the battery module to be inspected, in order to obtain the clearest image. An isolation lifting plate 203 is located on the side front of the industrial camera 202, driven by a vertically mounted cylinder. When the battery module is conveyed to the inspection station, the isolation lifting plate 203 descends, blocking the front of the battery module, serving two key functions: first, ensuring that the battery module being inspected is in the precise preset position at the moment of shooting; and second, preventing subsequent battery modules from entering the field of view and causing interference.

[0027] To obtain high-quality inspection images, this invention optimizes the internal structure of the industrial camera 202. For example... Figure 4 As shown, the industrial camera 202 contains an internal camera bracket 301 for fixing and supporting internal components. A ring light source 302, preferably an LED white light ring light source, is mounted on the bottom outer edge of the camera bracket 301. This light source can evenly illuminate the surface of the battery module from multiple angles, effectively eliminating shadows and reflections. A detection lens 303 is mounted at the central through-hole of the ring light source 302, facing the battery module below, for acquiring high-definition images of its top and sides.

[0028] The sorting pusher 7 is installed next to the side of the secondary conveyor belt 3 where the inspection is completed. In this embodiment, it preferably uses a cylinder with fast response and compact structure. The installation position of the sorting pusher 7 is precisely calculated to ensure that when its piston rod extends, it can accurately push the battery modules judged to be unqualified from the conveyor belt into the unqualified product collection box next to it.

[0029] The control system of this utility model is integrated within the storage cabinet 11, mainly comprising an industrial computer and a programmable logic controller (PLC). The industrial computer has built-in image processing software, integrating advanced machine vision algorithms such as edge extraction, speckle analysis, and template matching, used to perform real-time analysis of images transmitted from the industrial camera 202 and ultimately make a "qualified" or "unqualified" judgment. The PLC is responsible for receiving judgment signals from the industrial computer, position sensor signals from the conveyor belt, etc., and controlling the start and stop of each level of the conveyor belt, the reciprocating motion of the clamping assembly 5, the lifting and lowering of the isolation lifting plate 203, and the movement of the sorting push rod 7 according to the preset logic program. The display panel 4 is connected to the industrial computer for human-machine interaction.

[0030] The working process of this utility model is as follows: Loading: The operator or the robotic arm from the previous process places the battery module to be tested at the starting end of the primary conveyor belt 2. The primary conveyor belt 2 starts, transports the module to the designated gripping position, and then stops.

[0031] Transfer: The drive block 103 of the clamping component 5 drives the battery clamping plate 104 to move above the primary conveyor belt 2. The battery clamping plate 104 descends (or clamps) to pick up the battery module, and then slides laterally above the secondary conveyor belt 3. Finally, the battery module is released smoothly.

[0032] Conveying and Positioning: The secondary conveyor belt 3 starts, carrying the battery module towards the inspection station. When the battery module reaches the inspection station directly below the industrial camera 202, the photoelectric sensor is triggered. After receiving the signal, the PLC immediately controls the secondary conveyor belt 3 to stop and simultaneously controls the cylinder of the isolation lifting plate 203 to descend, thereby accurately positioning and isolating the battery module to be inspected.

[0033] Image Acquisition and Judgment: After the battery module comes to a standstill, the PLC sends a trigger signal to the industrial computer. The industrial computer controls the ring light source 302 to light up and commands the industrial camera 202 to complete an image acquisition. The acquired high-definition image is transmitted to the industrial computer. The image processing software uses a preset algorithm to perform defect analysis and provides a "qualified" or "unqualified" judgment result in a very short time, and sends the result to the PLC.

[0034] Sorting: If it is determined to be qualified: the PLC controls the isolation lifting plate 203 to rise, then starts the secondary conveyor belt 3, and the qualified battery module continues to be conveyed forward until it enters the next process or the qualified product collection area; if it is determined to be unqualified: the PLC will record the information and position of this unqualified product. When the unqualified module runs to the sorting station in front of the sorting push rod 7 along with the reset secondary conveyor belt 3, another sensor is triggered. The PLC then controls the solenoid valve of the sorting push rod 7 to be energized, the cylinder piston rod extends rapidly, and pushes the battery module decisively away from the conveyor belt into the unqualified product collection box. After sorting is completed, the sorting push rod 7 resets.

[0035] The above process repeats cycle after cycle, realizing full-process automation of battery module feeding, transferring, precise positioning, visual inspection and automatic sorting, which greatly improves production efficiency and consistency of product quality.

[0036] Matters not described in the present application can be implemented by adopting or referencing existing technologies.

[0037] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between various embodiments can be referred to each other. Each embodiment focuses on the differences from other embodiments.

[0038] The above description is only embodiments of the present application, and is not intended to limit the present application. Various modifications and changes to the present application are possible for those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present application shall be included in the scope of the claims of the present application.

Claims

1. An automatic sorting device for appearance defects in new energy vehicle battery modules, characterized in that, include: Mainframe rack; The conveying module is mounted on the main frame. The conveying module includes a primary conveyor belt for feeding and a secondary conveyor belt for detection. The primary conveyor belt and the secondary conveyor belt are adjacent to each other and parallel to each other, and their conveying directions are opposite. A clamping assembly is disposed above the primary conveyor belt and the secondary conveyor belt, for transferring the battery module from the primary conveyor belt to the secondary conveyor belt; A visual inspection component is disposed above the secondary conveyor belt and is used to inspect the appearance defects of the battery module. The sorting pusher is located on one side of the secondary conveyor belt next to the vision inspection component, and is used to push out the battery modules that fail the inspection. The system is electrically connected to the conveying module, clamping assembly, vision inspection assembly, and sorting push rod.

2. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The clamping assembly includes an upper fixed plate, a mating slide rail, a drive block, and a battery clamping plate; the upper fixed plate is horizontally disposed above the primary conveyor belt and the secondary conveyor belt, the mating slide rail is disposed on the upper fixed plate, the drive block slides in engagement with the mating slide rail, and the battery clamping plate is connected below the drive block.

3. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The vision inspection component includes a position adjustment frame, an industrial camera, and an isolation lifting plate. The position adjustment frame is positioned above the secondary conveyor belt, and the industrial camera is adjusted in height via the position adjustment frame. The isolation lifting plate is positioned next to the industrial camera and is used to isolate and position the battery module during inspection.

4. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 3, characterized in that: The industrial camera includes an internal camera support, a ring light source, and a detection lens; the ring light source is mounted on the bottom edge of the internal camera support, and the detection lens is located at the center of the ring light source.

5. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The device also includes a display panel and a storage cabinet; the display panel is mounted on the main frame and connected to the control system, and the storage cabinet is located inside the main frame.

6. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The primary conveyor belt and the secondary conveyor belt are at the same height.

7. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 3, characterized in that: The industrial camera is vertically aligned with the secondary conveyor belt.

8. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The sorting push rod is a pneumatic push rod or an electric push rod, and its action is controlled by the control system based on the detection results of the vision detection component.

9. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The control system is configured to: receive image data from the vision inspection component and perform defect analysis; if the defect is determined to be unqualified, control the sorting push rod to start when the battery module arrives at the sorting station and push it away from the secondary conveyor belt.

10. The automatic sorting device for appearance defects of new energy vehicle battery modules according to claim 1, characterized in that: The primary and secondary conveyor belts are each driven by an independent drive motor.

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