Four-station helium detection data acquisition device

Abstract

The utility model discloses a four position helium detection data acquisition device, including four position helium detection machine body, movable code scanning gun mechanism and data interaction storage system, movable code scanning gun mechanism is installed on the rack of helium detection machine body through support component, and it is by motor drive ball screw and linear guide, and drives code scanning gun to move to four work positions above in turn, and code scanning gun is installed through adjustable support and is equipped with light supplement module, positioning assembly ensures accurate scanning position, and data interaction storage system receives lithium battery cover product bar code that code scanning gun obtains and the helium detection result that helium detection machine control unit exports, and will the both associated storage, the utility model realized lithium battery cover product identity information and helium detection result's automatic, accurate binding, fundamentally avoided manual record error, provided reliable data intercept basis for later working procedure, effectively prevented the helium detection and unqualified product flow, promoted production quality and customer credibility.

Description

Technical Field

[0001] This utility model relates to the technical field of lithium battery cover plate testing equipment, specifically, to a four-station helium detection data acquisition device for testing the sealing performance of semi-finished lithium battery cover plates. Background Technology

[0002] As a key component of lithium batteries, the sealing performance of the lithium battery cover directly determines the safety and lifespan of the finished battery cell. Therefore, during the manufacturing process of lithium battery covers, rigorous helium sealing testing (hereinafter referred to as "helium testing") must be performed on them at the semi-finished product stage. To improve testing efficiency, the industry commonly uses semi-automatic four-station helium testing machines, which can test four products simultaneously.

[0003] However, existing four-station helium detectors focus on the detection of physical parameters, lacking a module for automatically linking and collecting "individual product identification information" with "corresponding helium detector results." Current operations heavily rely on manual labor: after helium detection, operators must manually record the barcode of each product at each station and manually match it with the station's detection result (pass / fail) before entering the data into a computer system or paper log. This process has two inherent flaws: first, in a fast-paced production environment, manual recording and matching are prone to errors due to fatigue and negligence, leading to mismatches between barcodes and results, resulting in qualified products being misjudged or unqualified products being missed; second, there is a lack of effective error prevention and traceability mechanisms for determining whether helium detection has been completed, potentially causing operators to mistakenly place untested products in the inspected area, allowing them to flow into subsequent processes.

[0004] Because subsequent battery packaging processes have limited independent identification capabilities regarding cover sealing, the aforementioned issues directly lead to the inability to effectively intercept some products that have not undergone helium testing or have failed helium testing, ultimately resulting in their reaching end customers. This can not only cause mass scrapping and customer claims due to cell leakage, resulting in huge economic losses, but also severely damage the company's brand reputation. Therefore, developing a device that can fundamentally solve the structural problem of automatically and accurately linking product information with test results and effectively preventing defective products from leaving the factory has become an urgent technical problem to be solved in this field. Utility Model Content

[0005] To address the problems existing in the prior art, this utility model provides a four-station helium detection data acquisition device. Through an integrated mechanical structure and data system, it realizes the automatic and accurate binding and storage of product barcodes and helium detection results, providing reliable data support for subsequent processes and thus preventing defective products from leaving the factory.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A four-station helium detection data acquisition device includes:

[0008] The four-station helium detector body includes a frame, a station support unit and a helium detection function unit mounted on the frame, and a control unit;

[0009] A movable barcode scanner mechanism is mounted on the frame via a support assembly; the movable barcode scanner mechanism also includes a movable drive assembly driven by a drive motor and capable of reciprocating along the workstation layout direction of the workstation bearing unit, a barcode scanning execution assembly fixed on the movable drive assembly, and a positioning assembly for detecting the position of the barcode scanning execution assembly.

[0010] The data interaction and storage system is communicatively connected to the control unit and the barcode scanning execution component, and is used to receive and associate the barcode information of the lithium battery cover plate product with the corresponding helium test result information.

[0011] Specifically, the support assembly includes a support beam and a bracket for fixing the support beam to the frame; the moving drive assembly includes a ball screw, a screw nut meshing with the ball screw, a drive motor for driving the ball screw, and a linear guide rail arranged parallel to the ball screw, wherein the screw nut is fixedly connected to a slider on the linear guide rail.

[0012] Specifically, the barcode scanning execution component includes a barcode scanner and an adjustable bracket for fixing the barcode scanner; the adjustable bracket can adjust the angle of the barcode scanner by ±30° in the horizontal plane and ±20° in the vertical plane.

[0013] Specifically, the scanning execution component also includes supplementary lighting modules symmetrically installed on both sides of the barcode scanner, and the light intensity of the supplementary lighting modules is adjustable in the range of 1000 to 3000 lux.

[0014] Specifically, the positioning component includes an origin sensor for calibrating the origin of movement of the barcode scanning execution component, and multiple position sensors for calibrating its alignment with each workstation.

[0015] Specifically, the data interaction and storage system includes a data acquisition module, a local storage module, and a host computer interface; the data acquisition module is an industrial gateway with data caching function, which is communicatively connected to the control unit and the barcode scanning execution component; the local storage module is a pluggable industrial-grade SD card; and the host computer interface is used to connect to an external host computer.

[0016] Specifically, the workstation support unit includes a workstation platform and positioning pins. The workstation platform is provided with four sets of workstations arranged side by side, and each set of workstations is provided with at least two positioning pins for positioning products.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] (1) This utility model achieves automatic binding of product identity information and helium inspection results through the coordinated work of the movable barcode scanner mechanism and the data interaction storage system, completely avoiding the mismatch problem that may be caused by manual recording. Based on the established helium inspection database, it enables the subsequent process to achieve accurate and reliable interception of defective products, effectively preventing the outflow of uninspected and unqualified products, and avoiding customer claims and batch rework.

[0019] (2) The scanning process of this utility model is seamlessly connected with the helium inspection process. It is automatically executed during the natural gap when the helium inspection is completed. Through optimized motion control, the total scanning cycle covering the four workstations takes a very short time, so that the overall inspection cycle of the equipment increases only slightly. While achieving full data collection, it maximizes production efficiency.

[0020] (3) The movable barcode scanner mechanism of this utility model adopts a modular design and can be conveniently installed on the existing helium detector through the bracket without structural damage to the original equipment. Furthermore, the barcode scanning execution component has multi-degree-of-freedom adjustment and adjustable supplementary lighting functions, which can adapt to lithium battery cover plates of different specifications and barcode states. It has strong versatility and is very suitable for low-cost and high-efficiency upgrades of existing production lines. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model.

[0022] Figure 2 This is a schematic diagram of the workstation support unit in an embodiment of the present invention.

[0023] Figure 3 This is a schematic diagram of the movable barcode scanner mechanism in an embodiment of the present invention.

[0024] Figure 4 This is a block diagram illustrating the control principle of an embodiment of the present invention.

[0025] In the above figures, the component names corresponding to the reference numerals are as follows:

[0026] 1-Frame, 2-Workstation support unit, 21-Workstation platform, 22-Positioning pin, 3-Helium detector functional unit, 4-Control unit, 5-Movable barcode scanner mechanism, 51-Support component, 511-Support beam, 512-Bracket, 52-Movement drive component, 521-Ball screw, 522-Drive motor, 523-Linear guide rail, 53-Scanning execution component, 531-Barcode scanner, 532-Adjustable bracket, 533-Fill-in light module, 54-Positioning component, 541-Position sensor, 542-Origin sensor, 6-Data interaction and storage system, 61-Data acquisition module, 62-Local storage module, 63-Host computer interface. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments. The embodiments of the present invention include, but are not limited to, the following embodiments.

[0028] Example

[0029] like Figures 1 to 4 As shown, the four-station helium detection data acquisition device is used to collect helium detection result data of lithium battery cover plates. It consists of three main parts: the four-station helium detector body, the movable barcode scanner mechanism 5, and the data interaction and storage system 6.

[0030] The four-station helium detector body includes a frame 1, station support units 2 and helium detection functional units 3 mounted on the frame, and a control unit 4. Specifically, the frame 1 is welded from Q235 carbon steel, with a stable structure and a powder-coated surface for rust prevention. A series of M8 threaded holes are pre-drilled along the length of the top of the frame 1 for convenient subsequent installation. The station support unit 2 includes a station platform 21 and multiple sets of positioning pins 22. The station platform is made of 6061 aluminum alloy plate and is mounted in the middle of the frame via shock-absorbing pads. Four stations are arranged side-by-side on its surface, each equipped with two cylindrical positioning pins 22 made of 45# steel for precise positioning of the lithium battery cover to be tested. The helium testing unit 3 includes four independent and sealed testing chambers, each corresponding to one workstation. Each chamber is equipped with a fluororubber sealing ring to ensure a tight seal during testing. Each chamber is connected to a high-precision helium sensor to detect leakage rates. A shared vacuum pump is connected to the four chambers via a piping system and controlled by solenoid valves. The control unit 4, based on a Siemens S7-200 SMART PLC controller, coordinates the entire helium testing process (e.g., controlling the vacuum pump and solenoid valves, and reading sensor data). It features a human-machine interface for displaying status and results and includes an alarm module. This PLC controller has an RS485 communication interface, allowing it to output the helium testing results (pass / fail) for each workstation.

[0031] The movable barcode scanner mechanism 5 includes a support assembly 51 on the frame, a moving drive assembly 52 mounted on the support assembly and reciprocating along the workstation layout direction of the workstation bearing unit, a barcode scanning execution assembly 53 fixed on the moving drive assembly, and a positioning assembly 54 for detecting the position of the barcode scanning execution assembly. Specifically, the support assembly 51 includes an aluminum alloy support beam 511, both ends of which are securely mounted on pre-drilled threaded holes on the top of the frame via L-shaped carbon steel brackets 512 and reinforcing ribs, ensuring the rigidity of the entire mechanism. The moving drive assembly 52 includes a ball screw 521, a screw nut meshing with the ball screw, a drive motor 522 driving the ball screw, and a linear guide rail 523 parallel to the ball screw. The screw nut is fixedly connected to a slider on the linear guide rail. The ball screw can be an SFU1605 type, mounted parallel to the support beam via a bearing housing, and can be configured with an effective stroke of 1200mm. The drive motor can be a 57HS22 type stepper motor, connected to one end of the ball screw via a flexible coupling. The driver of the drive motor receives commands from the control unit. The linear guide can be an MGN12 type linear guide, mounted parallel to the ball screw. The barcode scanning execution component 53 includes a barcode scanner 531 and an adjustable bracket 532 for fixing the barcode scanner. The barcode scanner can be an NVH200 industrial-grade 2D barcode scanner. The adjustable bracket is configured as a universal joint structure, fixed to the slider of the linear guide via a connecting plate, and can achieve horizontal ±30° and vertical ±20° angle adjustment for optimal alignment with the product barcode. Furthermore, supplementary lighting modules 533 are symmetrically installed on both sides of the barcode scanner 531. These modules can be strip LEDs, and their illumination intensity can be adjusted between 1000-3000 lux to handle complex situations such as barcode damage and glare. The positioning component 54 includes an origin sensor 542 for calibrating the origin of the scanning execution component's movement, and multiple position sensors 541 for calibrating its alignment with each workstation. The origin sensor can be an Omron E3Z-G61 slot-type photoelectric switch, installed at the initial position at one end of the crossbeam. The position sensors can be Omron E3Z-D61 diffuse reflection photoelectric switches, with the four position sensors respectively installed directly above the four workstations under the supporting crossbeam. The signals from both the origin sensor and the position sensors are connected to the control unit.

[0032] The data interaction and storage system 6 is communicatively connected to the control unit and the barcode scanning execution component, and is used to receive and associate the product barcode information with the corresponding helium detection result information. Specifically, the data interaction and storage system includes a data acquisition module 61, a local storage module 62, and a host computer interface 63. The data acquisition module is an industrial gateway with data caching function, such as the Advantech EKI-1221 industrial gateway, which is connected to the PLC controller via an RS485 cable and to the barcode scanner via an Ethernet cable to realize communication between barcode data and helium detection result data. The local storage module is a pluggable industrial-grade SD card, such as a 32GB industrial-grade SD card, which is inserted into the card slot of the data acquisition module for offline backup of all associated data to prevent data loss due to network failure. The data acquisition module itself also has a 1GB local cache, which can temporarily store data when the network is interrupted and automatically re-upload it after recovery. The host computer interface is a standard RJ45 Ethernet port, which can upload the acquired data to the factory's central server or MES system, or connect to a local computer for data query and management.

[0033] The working process of this utility model is as follows:

[0034] Initialization: After the device is powered on, the control unit 4 controls the drive motor 522 to drive the barcode scanning execution component 53 to move until the origin sensor 542 is triggered, completing the origin calibration. Each system performs a self-test.

[0035] Helium testing execution: The operator places four lithium battery covers into the workstation and presses the start button. The helium testing machine automatically performs the sealing, vacuuming, and helium filling testing process. After the test is completed, the PLC controller generates the helium testing results for the four workstations and sends a "test complete" signal.

[0036] Automatic barcode scanning and data association: A. After receiving the "detection complete" signal, the data acquisition module starts the drive motor 522 through the control unit. B. The barcode scanning execution component 53 moves towards station one. When it reaches above station one, the position sensor 541 is triggered, the control unit 4 stops the motor, the supplementary light module 533 lights up according to preset parameters, the barcode scanner 531 triggers scanning, and uploads the decoded barcode data to the data acquisition module. C. This process is repeated to complete the scanning of station two, station three, and station four in sequence. D. After acquiring all barcodes, the data acquisition module immediately obtains the corresponding helium detection result from the PLC controller and generates a complete data record in the format of "product barcode-station-helium detection result-timestamp".

[0037] Data storage and upload: The generated data records are simultaneously written to the local storage module and uploaded to the external system in real time via the host computer interface. In case of network failure, the data is temporarily stored in the gateway cache.

[0038] Anomaly Handling: If barcode scanning fails at a workstation, the system will alarm and pause, prompting operator intervention. If the helium dioxide test result is unqualified, the corresponding indicator light on the human-machine interface screen will turn red, reminding the operator to remove the defective product.

[0039] Cycle and Interception: After scanning, the mechanism resets, preparing for the next round of inspection. In subsequent processes (such as the shipping and packaging station), scanning the product barcode allows for database lookup; products with no record or those recorded as non-compliant will be precisely intercepted.

[0040] To verify the performance of this device, a continuous 72-hour operation test was conducted in a lithium battery production workshop, testing 5000 products. The test results are as follows:

[0041] Data accuracy: 4,995 products successfully completed data binding, achieving a success rate of 99.9%. The 5 failed products were all due to severe physical damage to the barcodes; after manual intervention, they were re-tested and successfully bound. No barcode mismatches occurred throughout the process.

[0042] Interception results: During the test, a total of 48 helium-tested defective products were generated, all of which were 100% intercepted in subsequent processes. Additionally, two untested products that were accidentally mixed in due to operator negligence were successfully intercepted.

[0043] Production efficiency: The total cycle of a single detection and data acquisition by the device is about 22 seconds, which is only 2 seconds longer than the pure detection cycle of about 20 seconds before the modification. The impact on production capacity is controlled within 10%, which fully meets the production cycle requirements.

[0044] Environmental adaptability: In normal workshop conditions, even when some product barcodes are oily, the scanning success rate remains above 99.8% by adjusting the supplementary light intensity, demonstrating its good industrial applicability.

[0045] The above embodiments are merely preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. Any changes made based on the design principles of this utility model, or any non-creative changes made on this basis, shall fall within the scope of protection of this utility model.

Claims

1. A four-station helium detection data acquisition device, characterized in that, include: The four-station helium detector body includes a frame (1), a station support unit (2) and a helium detection function unit (3) mounted on the frame (1), and a control unit (4). The movable barcode scanner mechanism (5) is mounted on the frame (1) via a support component (51); the movable barcode scanner mechanism (5) also includes a moving drive component (52) that reciprocates along the workstation arrangement direction of the workstation bearing unit (2), a barcode scanning execution component (53) fixed on the moving drive component, and a positioning component (54) for detecting the position of the barcode scanning execution component. The data interaction storage system (6) is communicatively connected to the control unit (4) and the barcode scanning execution component (53) for receiving and associating the storage of the barcode information of the lithium battery cover plate product with the corresponding helium detection result information.

2. The four-station helium detection data acquisition device according to claim 1, characterized in that, The support assembly (51) includes a support beam (511) and a bracket (512) for fixing the support beam (511) to the frame (1); the moving drive assembly includes a ball screw (521), a screw nut meshing with the ball screw (521), a drive motor (522) for driving the ball screw (521), and a linear guide rail (523) arranged parallel to the ball screw (521), wherein the screw nut is fixedly connected to a slider on the linear guide rail (523).

3. The four-station helium detection data acquisition device according to claim 2, characterized in that, The barcode scanning execution component (53) includes a barcode scanner (531) and an adjustable bracket (532) for fixing the barcode scanner (531); the adjustable bracket (532) can adjust the angle of the barcode scanner (531) by ±30° in the horizontal plane and ±20° in the vertical plane.

4. The four-station helium detection data acquisition device according to claim 3, characterized in that, The scanning execution component (53) also includes supplementary lighting modules (533) symmetrically installed on both sides of the barcode scanner (531), and the light intensity of the supplementary lighting modules (533) is adjustable in the range of 1000 to 3000 lux.

5. The four-station helium detection data acquisition device according to claim 2, characterized in that, The positioning component (54) includes an origin sensor (542) for calibrating the origin of the scanning execution component (53) and multiple position sensors (541) for calibrating its alignment with each workstation.

6. The four-station helium detection data acquisition device according to any one of claims 1 to 5, characterized in that, The data interaction storage system (6) includes a data acquisition module (61), a local storage module (62), and a host computer interface (63); the data acquisition module (61) is an industrial gateway with data caching function, which is connected to the control unit (4) and the barcode scanning execution component (53) respectively; the local storage module (62) is a pluggable industrial-grade SD card; the host computer interface (63) is used to connect to an external host computer.

7. The four-station helium detection data acquisition device according to claim 6, characterized in that, The workstation support unit (2) includes a workstation platform (21) and positioning pins (22). The workstation platform (21) is provided with four sets of workstations arranged side by side. Each set of workstations is provided with at least two positioning pins (22) for positioning lithium battery cover products.

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