INLINE BATTERY CELL LEAK DETECTION SYSTEM
The system addresses inefficiencies in battery cell leak detection by using a movable platform with gas introduction and infrared scanning, achieving high-throughput inline leak detection and integrity testing for battery cells, particularly in electric vehicles.
Patent Information
- Application Number
- DE102024132754
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2024-09-18
- Filing Date
- 2024-11-11
- Publication Date
- 2025-10-16
- Estimated Expiration
- 2044-11-11
AI Technical Summary
Existing systems for testing the tightness of battery cells are inefficient and lack the capability to perform inline leak detection during the manufacturing process, particularly for battery cells used in electric vehicles, with a need for improved integrity checks before and after electrolyte introduction.
A system utilizing a movable platform with test stations and probes to introduce gas into battery cells, combined with an infrared camera for detecting leaks, capable of scanning up to 1,800 cells per hour, and ensuring structural integrity checks before and after electrolyte addition.
Enables efficient inline leak detection and integrity testing of battery cells, ensuring high throughput and reliable detection of leaks and structural integrity, enhancing manufacturing efficiency and quality assurance.
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Abstract
Description
INTRODUCTION
[0001] The present invention relates to a system for inline leak detection of battery cells.
[0002] Battery cells are used to power a wide variety of devices and systems. For example, battery cells are power sources for battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and hybrid electric vehicles (HEVs). Different types of battery cells can be used, including cylindrical battery cells. Each cell includes an outer casing that is sealed to prevent its contents from leaking out of the cell. Quality controls are performed during battery cell manufacturing to ensure the integrity of each individual battery cell.
[0003] From JP 3 248 011 U a system is known which is configured for testing the leak tightness of battery cells, the system comprising a movable platform and a plurality of test stations, each of the plurality of test stations being configured to interact with a pallet on which the battery cells rest, each of the plurality of test stations comprising probes which can be moved in interaction with the battery cells and are configured to introduce gas into each of the battery cells.
[0004] From DE 10 2021 120 269 A1 a system for testing the tightness of traction battery housings is known, which comprises an infrared camera configured to detect leakage of a gas introduced into the housing, such as CO2, from the interior of the housing.
[0005] From CN 2 19 178 832 U a system for testing the tightness of battery cells is known, which comprises an infrared camera configured to detect the escape of a gas introduced into the battery cell from the battery cell. SUMMARY
[0006] According to the invention, a system having the features of claim 1 is presented, which is configured for testing battery cells.
[0007] The system comprises: a movable platform; a plurality of test stations movable by the movable platform, each of the plurality of test stations configured to interact with a pallet upon which the battery cells rest, each of the plurality of test stations including probes movable to interact with the battery cells and configured to introduce gas into each of the battery cells; and a camera adjacent to the movable platform and configured to detect a leak of the gas from within one of the battery cells.
[0008] In other features, the moving platform is circular.
[0009] Additional features include an infeed conveyor configured to transport the pallet to the moving platform and an outfeed conveyor configured to transport the pallet away from the moving platform after the battery cells have been scanned by the camera.
[0010] In further features, each of the plurality of test stations includes an entrance gate and an exit gate spaced apart from each other to receive the pallet therebetween, wherein both the entrance gate and the exit gate are configured to be opened and closed to facilitate transport of the pallet to and from the plurality of test stations.
[0011] In other features, the probes are vertically movable.
[0012] In other characteristics, the gas is carbon dioxide.
[0013] In further features, the camera is an infrared camera with a filter configured to block the transmission of infrared radiation outside a wavelength range of 4-5 µm.
[0014] In further features, each of the plurality of test stations further comprises a back wall on a side of the pallet opposite the camera, the back wall being configured as a background radiation source for the camera and being configured to be heated to a temperature of 10°C - 30°C above ambient temperature.
[0015] In further features, a pump is configured to pump the gas through the probes to the battery cells at a pressure of no more than 1 psi.
[0016] In further features, the gas introduced into the battery cells is a first gas introduced into the battery cells prior to the addition of an electrolyte; and the camera is further configured to detect the escape of a second gas from within one of the battery cells following the installation of an anode, a cathode, and an electrolyte, wherein the second gas is different from the first gas.
[0017] In further features, the camera is an infrared camera with a filter configured to block the transmission of infrared radiation outside a wavelength range of 5-12 µm to detect the second gas.
[0018] In further features, the movable platform is configured to move a first station of the plurality of test stations to a first position in which a first pallet having a first group of battery cells thereon is coupled to the first station between an entrance gate and an exit gate of the first station, the battery cells not containing electrolyte; the movable platform is configured to move the first station to a second position in which a carrier is configured to move the probes into contact with the battery cells and a pump is configured to pump gas through the probes into the battery cells; the movable platform is configured to move the first station to a third position in which the probes remain in contact with the battery cells and the battery cells remain filled with the gas;the movable platform is configured to move the first station to a fourth position in which the camera is configured to scan the battery cells for gas leakage from inside the battery cells, and the carrier is configured to move the probes away from contact with the battery cells after the camera has scanned the battery cells for gas leakage; the movable platform is configured to move the first station to a fifth position in which the exit gate is configured to open to allow the pallet to be transported away from the movable platform; and the movable platform is configured to move the first station back to the first position to receive an additional pallet containing additional battery cells for testing.;
[0019] In further features, the pallet and the additional pallet are equipped with identification labels to track the movement and results of the camera.
[0020] In further features, the plurality of test stations includes the first station and seven additional stations identical to the first station in order to test additional battery cells simultaneously.
[0021] The present invention also includes, in various features, a system configured for testing battery cells, the system comprising: a rotatable platform; a plurality of test stations spaced in a circle around the rotatable platform and configured to rotate with the rotatable platform; probes included in each of the plurality of test stations, the probes vertically movable for interaction with the battery cells and configured to introduce gas into the battery cells; an infrared camera adjacent to the rotatable platform and configured to detect the escape of gas from within one of the battery cells; an infeed conveyor belt interacting with the rotatable platform and configured to feed the battery cells to the rotatable platform;and an outfeed conveyor that interacts with the rotating platform to guide the battery cells away from the rotating platform.;
[0022] In further features, each of the plurality of test stations includes a heated back wall configured as a background radiation source for the infrared camera.
[0023] In further features, the infrared camera includes a filter configured to block the transmission of infrared radiation outside a wavelength of 4-5 µm.
[0024] Further, a method for testing battery cells is described. The method includes: transporting pallets with the battery cells thereon to a rotatable platform containing a plurality of test stations, the plurality of test stations containing probes that can be moved to interact with the battery cells and are configured to introduce gas into the battery cells; coupling the pallets to the plurality of test stations; moving the probes to interact with openings defined by the battery cells; introducing gas through the probes and into the battery cells through the openings; rotating the rotatable platform to move the plurality of test stations and the battery cells to an infrared camera configured to detect a leak of gas from inside any of the battery cells;and, when the openings of the battery cells are sealed by the probes, activating the infrared camera to detect any leakage of gas from the interior of any of the battery cells in areas outside the openings, and assessing the structural integrity of the battery cells based on the detection of the gas leaked from the interior of the battery cells.;
[0025] In further features, the method comprises moving the pallets with the battery cells thereon to the rotatable platform via an infeed conveyor in interaction with the rotatable platform and moving the pallets with the battery cells thereon away from the rotatable platform via an outfeed conveyor in interaction with the rotatable platform.
[0026] In further features, the gas is a first gas, the method further comprising, after sealing the openings of the battery cells, activating the infrared camera to detect the escape of a second gas from the interior of the battery cells, the second gas being different from the first gas.
[0027] Further areas of applicability of the present invention will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are provided for illustrative purposes only. BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present invention will be better understood from the detailed description and the accompanying drawings, in which: Fig. 1 is a plan view of an exemplary system according to the present invention configured for testing battery cells; Fig. 2 is a perspective view of an exemplary test station of the system of Fig. 1; Fig. 3 is a perspective view of an exemplary battery cell for which the system of Fig. 1 is configured for testing; Fig. 4 illustrates features of an exemplary method according to the present invention for testing battery cells; Fig. 5 illustrates additional features of an exemplary method according to the present invention for testing battery cells; Fig. 6 illustrates further features of an exemplary method according to the present invention for testing battery cells; Fig. 7 illustrates further additional features of an exemplary method according to the present invention for testing battery cells; and Fig. 8 illustrates additional features of an exemplary method according to the present invention for testing battery cells.
[0029] Reference numerals may be reused in the drawings to identify similar and / or identical elements. DETAILED DESCRIPTION
[0030] The present invention is directed to systems and methods for inline leak detection of battery cells. The systems and methods can be used to test any suitable battery cells configured to power any suitable device. The battery cells can be, for example, cylindrical battery cells. The battery cells can be configured to power any device, such as a vehicle. With respect to vehicles, the battery cells can be configured to power, for example, battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), or hybrid electric vehicles (HEVs). The battery cells can also be configured for any other suitable non-automotive use. The systems and methods of the present invention are therefore suitable for both automotive and non-automotive applications.
[0031] The battery cells may be manufactured using any suitable manufacturing process. Example manufacturing processes include sealing one or more components of an outer casing, e.g., by welding or otherwise attaching a cover to the shell. The cover may be sealed, for example, prior to the addition of electrolyte. The present invention provides systems and methods for testing the integrity of the battery cells, e.g., the integrity of the cover's seal. Testing may be performed prior to the introduction of the electrolyte by introducing a trace gas (e.g., carbon dioxide) into the battery cells and then scanning the battery cells with a suitable sensor for leakage of the gas. Suitable sensors include, but are not limited to, an infrared camera configured to detect carbon dioxide.The systems and methods of the present invention are configured to scan a very large number of battery cells inline for leaks during battery cell manufacturing. For example, the systems and methods of the present invention are configured to scan at least 1,800 battery cells per hour. After electrolyte introduction, the present invention is also configured to scan the battery cells inline for possible electrolyte leakage.
[0032] Fig. 1 illustrates an exemplary battery cell testing system 10 according to the present invention. The system 10 generally includes a movable platform 20, which may take the form of a rotatable pedestal, as illustrated, or other transport device or system configured to transport battery cells within the system 10. A motor 22 is included and configured to move the movable platform 20. The motor 22 may be configured to rotate the movable platform 20 in the illustrated example. The system 10 includes an infeed conveyor 30 configured to transport batteries to the movable platform 20 and an outfeed conveyor 32 configured to transport batteries away from the movable platform 20.As described herein, the movable platform 20 enables inline battery inspection and testing, improving the battery assembly and testing process. The system 10 is configured to process, for example, 1,800 battery cells per hour.
[0033] The batteries are transported through the system 10 on pallets 40 or other suitable movable platforms. The pallets 40 may be sized and shaped to accommodate any number of batteries, for example, three cylindrical battery cells 210, as in the examples of Fig. 1 and Fig. 2 illustrates. Fig. 3 illustrates an exemplary battery cell 210, which is further described herein.
[0034] The system 10 includes a plurality of test stations for testing the battery cells 210. The test stations are mounted on the movable platform 20 and are moved with the rotating platform 20. In the Fig. 1, the test stations rotate with the movable platform 20. The movable platform 20 may include eight test stations: a first test station 50A; a second test station 50B; a third test station 50C; a fourth test station 50D; a fifth test station 50E; a sixth test station 50F; a seventh test station 50G; and an eighth test station 50H. The test stations 50A-50H are arranged at equal intervals around the rotatable platform 20, which in the illustrated example is a circular turntable.
[0035] By rotating the movable platform 20 using the motor 22, the test stations 50A-50H are moved into different test positions. In the example of Fig. 1, the first test station 50A is located in a first test position A; the second test station 50B is located in a second test position B; the third test station 50C is located in a third test position C; the fourth test station 50D is located in a fourth test position D; the fifth test station 50E is located in a fifth test position E; the sixth test station 50F is located in a sixth test position F; the seventh test station 50G is located in a seventh test position G; and the eighth test station 50H is located in an eighth test position H. The movable platform 20 is rotatable counterclockwise in 45° increments by the motor 22. Thus, the movable platform 20 is rotatable to move the first test station 50A from the first position A to the second position B, to move the second test station 50B from the second position B to the third position C, etc.The other test stations 50B-50H can also be moved with the platform to the different test positions AH.
[0036] Test stations 50A-50H are identical or essentially identical to each other. Fig. 2 illustrates the first test station 50A, which is described in more detail below. The description of the first test station 50A also applies to the test stations 50B-50H. The first test station 50A includes an entrance gate 60 and an exit gate 62, both of which are movable to control the entry and exit of one of the pallets 40 in interaction with the first test station 50A. With the entrance gate 60 open and the exit gate 62 closed, for example, the pallet 40 containing three battery cells 210 can be transported to the first test station 50A. The entrance gate 60 is then closed to secure the pallet between the entrance gate 60 and the exit gate 62. As a result, the pallet 40 rotates with the first test station 50A as the movable platform 20 rotates the first test station 50A to the various positions AH.Each of the other test stations 50A-50H is configured to interact with a different pallet 40 to move the pallets 40 with the battery cells 210 thereon to the various positions AH. Each of the pallets 40 includes an identification tag 42, such as an RF-ID tag or other suitable tracking tag or other tracking function.
[0037] The first test station 50A further includes a tower 70 on which a carrier 72 is mounted. The carrier 72 is moved vertically along the tower 70 by a pneumatic cylinder 74 or other suitable actuating device. A plurality of probes 80 are attached to the carrier 72. Each probe 80 extends from a housing 82 that is in fluid communication with a pump 90 and a gas source. The pump 90 is configured to pump any suitable gas at any suitable pressure (e.g., 1 psi) to the housings 82 and through the probes 80 to the battery cells 210, as described herein. Any suitable gas may be used, e.g., carbon dioxide.
[0038] The probes 80 can be moved vertically toward and away from the battery cells 210 by the carrier 72. The pneumatic cylinder 74 is configured to move vertically by 100 mm or approximately 100 mm.
[0039] The system 10 further includes a camera 110, which is any suitable sensor configured to detect trace gas (e.g., carbon dioxide, CO2) escaping from the interior of the battery cell 210. The camera 110 is positioned around the movable platform. In the example of Fig. 1, the camera 110 is positioned in station D. The camera 110 may be configured as an infrared camera with a filter configured to block the transmission of infrared radiation outside a wavelength of 4-5 µm in order to detect any traces of gas, such as CO2, escaping from the interior of the battery cell 210. Each test station 50A-50H further includes a back wall 120 behind the pallet 40 containing the battery cells 210. In test station D, the back wall 120 is located on a side of the battery cells 210 opposite the camera 110. The battery cells 210 are thus located between the camera 110 and the back wall 120. The back wall 120 is configured to be heated above ambient temperature to a temperature of 10°C - 30°C above ambient temperature.The camera 110 is configured to capture mid-wave infrared (MWIR) images of the battery cells 210, with the backplane 120 serving as a background board, as further described herein.
[0040] Fig. 3 illustrates an example of a battery cell 210. The battery cell 210 is configured as a cylindrical cell. The battery cell testing system 10 can be configured to evaluate the integrity of any other suitable battery cell. The battery cell 210 generally includes a shell 212 and a cover 214 (or lid) sealed to the shell 212 with a suitable gasket 216. A central aperture 220 is located in the center of the cover 214. The central aperture 220 can be configured as a fill port, e.g., for filling the battery cell 210 with an electrolyte. Prior to filling the cell with the electrolyte, the system 10 is configured to test the integrity of the seal 216, as described herein. After the battery cell 210 is filled with the electrolyte (and an anode and a cathode are placed therein), the central aperture 220 is closed and sealed.The system 10 is further configured to also evaluate the structural integrity of the sealed central aperture 220, as described herein.
[0041] The system 10 further includes a control module 150 configured to control the system 10 or another suitable battery cell testing system to provide the described functions. For example, the control module 150 communicates with the motor 22 to actuate the motor 22 and rotate the movable platform 20 as described. The control module 150 further communicates with each of the test stations 50A-50H to move the probes 80 to and from the central apertures 220, as described herein. The control module 150 is configured to actuate the pump 90 to pump gas through the probes 80 and through the central apertures 220 and is configured to actuate the camera 110 to detect any gas that has leaked through the seal 216 or at another relevant location. The control module 150 is further configured to control the operation of the input gate 60 and the output gate 62.
[0042] In some applications, the control module 150 may be further configured to actuate the pump 90 or other suitable vacuum generating device to create a vacuum at a seal closing the central aperture 220 to test whether the seal at the central aperture 220 is sufficient to retain the electrolyte and other contents of the battery cell 210 within the battery cell 210. In such applications, the control module 150 is configured to actuate the camera 110 to identify any electrolyte or other vapors, gases, etc., drawn from the interior of the battery cell 210 by the vacuum created by the probes 80. The camera 110 includes a filter configured to block the transmission of infrared radiation outside a wavelength range of 5-12 µm.
[0043] The control module 150 can be configured to rotate the movable platform 20 so that each test station 50A-50H spends a predetermined period of time in each position AH, for example, 5 seconds in each position AH and 1 second transitioning between positions AH. Fig. 4 illustrates an exemplary method 310 for operating the system 10. The method 310, as well as the methods 410, 510, 610, and 710 set forth herein, will now be described primarily with respect to the first test station 50A, but the methods also apply to the test stations 50B-50H.
[0044] In block 312 of method 310, the control module 150 actuates the motor 22 to rotate the first test station 50A to the first position A, and in block 314, the control module 150 actuates a suitable motor or actuating mechanism to close the exit gate 62. In this phase of method 310, the entry gate 60 is opened by the release of a previous pallet 40. In block 316, the control module 150 actuates the infeed conveyor 30 to move the pallet 40 carrying the battery cells 210 past the open entry gate 60 to the first position A. The closed exit gate 62 prevents the pallet 40 from passing past the first position A. In this phase, the battery cells 210 each include the shell 212 and the cover 214, which is sealed to the shell 212 at the gasket 216. The central aperture 220 is open and there is no electrolyte in the battery cells 210.
[0045] In block 318, the pallet 40 arrives at the first test station 50A, located in the first position A. In block 320, the control module 150 is configured to close the entrance gate 60 in any suitable manner, such as by actuating a motor in interaction with the entrance gate 60. When the pallet 40 is between the closed entrance gate 60 and the closed exit gate 62, the pallet 40 is coupled to the first test station 50A to rotate with the first test station 50A from the first position A to the fifth station E, as described herein. In block 322, the identification tag 42 of the pallet 40 is read using any suitable scanning device. The identification tag 42 provides various information about the battery cells 210 on the pallet 40.The identification label 42 may, for example, indicate the battery cell type, the seal 216 type, the seal 216 date, the part and batch number, the end use, the date of manufacture, etc. If various predetermined conditions are met in block 324, the control module 150 causes the method to proceed to block 326, where the control module 150 actuates the pneumatic cylinder 74 to lower the carrier 72 and the probes 80 and seal them against the central apertures 220. After the probes 80 are lowered, the method 310 proceeds to block 330, where the first position A cycle is completed. If the predetermined conditions in block 324 are not met, the method 310 skips block 326 and proceeds directly from block 324 to block 330.
[0046] Fig. 5 illustrates another method 410 according to the present invention for operating the system 10 in the second position B. In block 412, the control module 150 actuates the motor 22 to rotate the movable platform 20 to further move the first test station 50A from the first position A to the second position B. In block 414, the control module 150 checks whether the probes 80 are still extended to the central apertures 220. If the probes 80 are still extended, the control module 150 actuates the pump 90 in block 416 to pump a suitable gas (e.g., CO2) through the probes 80 and through the open central apertures 220 into the battery cells 210. In block 420, the operating cycle in the second position B is completed. From the second position B, the control module 150 is configured to actuate the motor 22 to rotate the first test station 50A to the third position C.In the third position C, no action is taken on the battery cells 210.
[0047] Fig. 6 illustrates a method 510 for operating the system 10 in the fourth position D. In block 512, the control module 150 is configured to operate the motor to rotate the movable platform 20 to move the first test station 50A from the third position C to the fourth position D. As previously explained, the camera 110 is mounted in the fourth position D. In block 514, the control module 150 is configured to operate the camera 110 to check the battery cell 210 for leakage of the gas pumped into the battery cells 210 by the probes 80, which are still at the central aperture 220, to close the central aperture 220. The control module 150 operates the camera 110 to capture one or more infrared images of each of the battery cells 210.
[0048] In block 516, after capturing and optionally storing midwave infrared (MWIR) images in a suitable storage device of the control module 150 (or in conjunction with the control module 150), the control module 150 is configured to analyze the captured infrared images to determine whether or not gas leakage is present at the seal 216 or at another relevant location of the battery cell 210 (e.g., at the shell 212 or the cover 214). In one example, an image analysis module of the control module 150 examines each infrared image captured by the camera 110 to evaluate MWIR waves traveling between the heated backplane 120 and the battery cell 210 (e.g., along a top edge of the battery cell 210 at the seal 216).The image analysis module of the control module 150 may use any suitable algorithm for modeling gas clouds, for example, to locate one or more aberrations within the imaged MWIR waves. The control module 150 is configured to determine that any deviation is caused by compressed CO2 gas (or other suitable gas introduced into the battery cells 210 by the probes 80) leaking from the battery cell 210 (e.g., leaking from the seal 216, which has been broken or otherwise compromised).
[0049] In block 516, the control module 150 determines whether a gas leak has been detected or a predetermined verification period has elapsed without a leak being detected. The predetermined verification period may, for example, be 4.5 seconds or another suitable verification period. Once a gas leak has been detected or the predetermined verification period has elapsed, the control module proceeds from block 516 to block 518. In block 518, the control module 150 terminates the verification by the camera 110, and in block 520, the results of the verification are recorded and associated with the identification tag 42. From block 520, the method 510 proceeds to block 522, where the control module actuates the pneumatic cylinder to lift the probes 80 out of interaction with the central aperture 220 of the battery cell 210.
[0050] After method 510, the control module 150 proceeds to method 610 of Fig. 7, which controls the operation of the system 10 in the fifth position E. In block 612, the control module 150 actuates the motor 22 to rotate the first test station 50A to the fifth position E. In block 614, the control module 150 reads the identification tag using a suitable scanning device. In block 616, the control module 150 checks the data associated with the identification tag 42 for completeness (e.g., completeness of the camera verification results). If the data is complete, the control module 150 proceeds to block 618, where the control module 150 is configured to actuate the pneumatic cylinder 74 to raise the carrier 72, thereby lifting the probes 80 out of interaction with the battery cells 210.
[0051] After the probes 80 have been raised, the control module 150 is configured to open the exit gate 62 in block 620. With the exit gate 62 open, the outfeed conveyor 32 can pull the pallet 40 off the movable platform 20 and out of the system 10 to a subsequent manufacturing / test location. After the pallet 40 leaves the system 10, the control module 150 opens the entry gate 60 in preparation for receiving another pallet 40 containing additional battery cells 210 for inspection. In block 628, operation at the fifth station E is completed, and the control module 150 is configured to actuate the motor 22 to rotate the platform 20 in 45° increments through the sixth station F, the seventh station G, and the eighth station H. No operations occur at the sixth station F, the seventh station G, and the eighth station H.From the eighth station H, the first test station 50A is rotated back to the first position A, where another pallet 40 is picked up to check the battery cells 210 located thereon.
[0052] Fig.8 illustrates an overall method 710 for operation of the system 10 by the control module. In block 712, the control module 150 holds the movable platform 20 and the test stations 50A-50H in each position AH for a predetermined period of time to allow processing to occur at each station, such as the verification by the camera 110 in the fourth position D. The predetermined period of time may be, for example, 5 seconds. Once the predetermined period of time measured by the control module 150 has elapsed, the method 710 proceeds to block 714 where the control module 150 determines whether processing is complete at all test stations 50A-50H. For example, the control module 150 determines whether the verification by the camera 110 is complete and whether the gas injection in the first position A is complete. If not all stations are complete, the method 710 proceeds to block 716 where the control module 150 issues a cycle over warning.In response to the warning, an operator may check the system 10 for a fault. If the control module 150 determines in block 714 that all stations are complete, the control module 150 actuates the motor 22 in block 718 to advance the movable platform by 45°. Once the advance is complete, the method 710 returns to block 712.
[0053] The system 10 and corresponding methods 310-610 may also be configured to detect the leakage of electrolyte and electrolyte-related vapors through the seal 216 or the central aperture 220 after the electrolyte has been introduced into the battery cells 210. The operation of the probes 80 is modified to create a vacuum in an attempt to draw electrolyte-related vapors from within the battery cells 210 through the seal 216 or a seal at the central aperture 220. The camera 110 is modified with a filter configured to block the transmission of infrared radiation outside a wavelength range of 5-12 µm to detect the electrolyte-related vapors. In the fourth position D, the control module 150 actuates the camera 110 to scan for electrolyte-related vapors that may escape through the seal 216 or the sealed central aperture 220.Any of the battery cells 210 exhibiting leaks may be identified and treated accordingly.
Claims
[1] System (10) configured to test battery cells (210), the system (10) comprising: a movable platform (20); a plurality of test stations (50A-50H) that can be moved by the movable platform (20), each of the plurality of test stations (50A-50H) being configured to interact with a pallet (40) on which the battery cells (210) rest, each of the plurality of test stations (50A-50H) comprising probes (80) that can be moved in interaction with the battery cells (210) and are configured to introduce gas into each of the battery cells (210); and a camera (110) adjacent to the movable platform (20) and configured to detect a leakage of gas from inside one of the battery cells (210). [2] System (10) according to claim 1, wherein the movable platform (20) is circular. [3] System (10) according to claim 1, further comprising an inlet conveyor belt (30) configured to transport the pallet (40) to the movable platform (20), and an outlet conveyor belt (32) configured to transport the pallet (40) away from the movable platform (20) after the battery cells (210) have been scanned by the camera (110). [4] System (10) according to claim 1, wherein each of the plurality of test stations (50A-50H) includes an inlet gate (60) and an outlet gate (62) spaced apart to accommodate the pallet (40) between them, wherein both the inlet gate (60) and the outlet gate (62) are configured to be opened and closed to allow the transport of the pallet (40) to and from the plurality of test stations (50A-50H). [5] System (10) according to claim 1, wherein the probes (80) are vertically movable. [6] System (10) according to claim 1, wherein the gas is carbon dioxide. [7] System (10) according to claim 1, wherein the camera (110) is an infrared camera which includes a filter configured to block the transmission of infrared radiation outside a wavelength range of 4-5 µm. [8] System (10) according to claim 1, wherein each of the plurality of test stations (50A-50H) further comprises a back wall (120) on one side of the pallet (40) opposite the camera (110), wherein the back wall (120) is configured as a background radiation source for the camera (110) and is configured to be heated to a temperature of 10 °C - 30 °C above the ambient temperature. [9] System (10) according to claim 1, further comprising a pump (90) configured such that the gas is pumped through the probes (80) to the battery cells (210) at a pressure of at most 1 psi. [10] System (10) according to claim 1, wherein the gas introduced into the battery cells (210) is a first gas that is introduced into the battery cells (210) before the addition of an electrolyte; and the camera (110) is further configured to detect the escape of a second gas from the interior of one of the battery cells (210) after the installation of an anode, a cathode and an electrolyte, wherein the second gas differs from the first gas.
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