Tab ultrasonic welding detection system and spot check method

Abstract

A tab ultrasonic welding detection system (1) and a spot check method, relating to the technical field of batteries. The detection system comprises a calibration block (2), a first camera (31), a second camera (32), a first strip-shaped light source (41), a second strip-shaped light source (42), and a superordinate computer (5). A first film (101) and a second film (102) are respectively attached to the surfaces of a first tab profiled body (23) and a second tab profiled body (24) of the calibration block (2). The first camera (31) and the second camera (32) are respectively used for collecting detection images of the first film (101) and the second film (102). The first strip-shaped light source (41) and the second strip-shaped light source (42) are both configured to irradiate the first tab profiled body (23) and the second tab profiled body (24) at the same time. The superordinate computer (5) is configured to determine a hardware spot check result on the basis of the detection images, and is further configured to determine a software spot check result of the vision detection software in the superordinate computer (5) on the basis of a preset tab state image. The detection system can solve the problem of incapability of determining the reliability of the detection system, and is beneficial to discovering the abnormal state in time to a certain extent, so that outflow of defective products is avoided.

Description

Tab ultrasonic welding detection system and inspection method

[0001] Cross-references

[0002] This application refers to Chinese Patent Application No. 202410197243.2, filed on February 22, 2024, entitled “Tab Ultrasonic Welding Detection System and Inspection Method,” which is incorporated into this application in its entirety by reference. Technical Field

[0003] The present application relates to the field of battery technology, and in particular to a tab ultrasonic welding detection system and inspection method. Background Art

[0004] Defects may occur during the battery production process, and various inspection methods are needed to detect these defects and improve battery yield. For the ultrasonic welding process of battery tabs, the relevant technology typically uses a tab ultrasonic welding inspection system to test the welding quality of the battery tabs, thereby preventing the release of defective products. If the reliability of this inspection system decreases, the adverse consequence may be the release of a large number of defective products. Therefore, the tab ultrasonic welding system needs to be able to determine the reliability of its inspection results.

[0005] Summary of the Invention

[0006] The present application aims to solve at least one of the technical problems that exist in some situations. To this end, one object of the present application is to provide a tab ultrasonic welding detection system and inspection method, which can perform spot checks on the reliability of the system itself, thereby preventing the system from operating in a low-reliability state and resulting in a large number of defective products being shipped.

[0007] An embodiment of the first aspect of the present application provides a tab ultrasonic welding detection system, which includes a calibration block, a first camera, a second camera, a first strip light source, a second strip light source, and a host computer.

[0008] The calibration block includes a first battery shaped body, a second battery shaped body, a first tab shaped body, a second tab shaped body, a first film sheet and a second film sheet. The first battery shaped body is connected to the second battery shaped body through the first tab shaped body and the second tab shaped body. The first film sheet is attached to the surface of the first tab shaped body, and the second film sheet is attached to the surface of the second tab shaped body.

[0009] The first camera and the second camera are arranged along the first direction and are respectively located directly above the first tab profile and the second tab profile; the first camera is used to capture the detection image of the first film, and the second camera is used to capture the detection image of the second film.

[0010] The first bar light source and the second bar light source are respectively located on both sides of the first camera and the second camera along a second direction perpendicular to the first direction, and are both configured to illuminate the first tab contour and the second tab contour simultaneously.

[0011] The host computer is configured to determine the hardware inspection results of the first camera, the second camera, the first strip light source and the second strip light source based on the detection images captured by the first camera and the second camera; the host computer is also configured to determine the software inspection results of the visual inspection software in the host computer based on the preset tab status image.

[0012] In the technical solution of the embodiments of the present application, by configuring a calibration block for the tab ultrasonic welding detection system and enabling the host computer to determine hardware and software inspection results, the reliability of the detection system itself can be inspected, which facilitates the timely detection of abnormal conditions in the tab ultrasonic welding detection system, thereby preventing the tab ultrasonic welding detection system from operating in a state of low reliability, resulting in the outflow of a large number of defective products. Because the host computer is configured to perform inspections at both the hardware and software levels and to determine the hardware and software inspection results separately, the system's hardware or software can be debugged in a targeted manner, which helps shorten the debugging time of the detection system and, to a certain extent, improve the overall efficiency of the tab ultrasonic welding process.

[0013] In some embodiments, the surfaces of the first and second tab profiles facing the first and second cameras are each provided with a groove, the groove being used to accommodate the first and second films, such that the upper surfaces of the first and second films are flush with the surfaces of the first and second tab profiles, respectively. Thus, after the first and second films are respectively attached, the first and second tab profiles can simulate the actual flat tab surface, and can also, to a certain extent, reduce errors caused by the difference in film surface height and actual tab height, thereby, to a certain extent, facilitating consistency between hardware inspection results and actual tab welding inspections.

[0014] In some embodiments, the first film sheet and the second film sheet each include multiple rectangular areas, each rectangular area including a circular color block and a shaped color block surrounding the circular color block. The radii of the multiple circular color blocks are different, and the grayscale values ​​of the multiple shaped color blocks are different. The radii of the multiple circular color blocks are used to perform a spot check on the reliability of the tab ultrasonic welding detection system's size recognition, and the grayscale values ​​of the multiple shaped color blocks are used to perform a spot check on the reliability of the tab ultrasonic welding detection system's grayscale value recognition. Therefore, since there are at least two special-shaped color blocks with different grayscale values ​​and two circular color blocks with different radii, this not only can provide different grayscale values ​​and radii for the tab ultrasonic welding detection system to detect and identify, reducing the risk of false detection of a single detection target and playing a role in fool-proof inspection, but also can identify the difference between different grayscale values ​​in the detection image and compare it with the difference between the corresponding grayscale values ​​on the film, or identify the difference between different radii in the detection image and compare it with the difference between the corresponding radii on the film, the detection capability and detection accuracy of the tab ultrasonic welding detection system can be tested from different angles, thereby improving the reliability of the hardware inspection results of the tab ultrasonic welding detection system.

[0015] In some embodiments, along a first preset path that passes through each rectangular area in sequence, the grayscale value of the irregularly shaped color block gradually increases or decreases; the smallest radius of the plurality of circular color blocks is greater than or equal to the minimum detection size of the first camera and the second camera, and along a second preset path that passes through each rectangular area in sequence, the radius of the circular color block increases or decreases by integer multiples of the minimum detection size. Thus, through the above two preset paths, the grayscale value of the irregularly shaped color block and the radius of the circular color block both increase or decrease along the path. Therefore, during spot inspections, the tab ultrasonic welding inspection system can compare the grayscale value and radius obtained to determine whether they meet the preset variation pattern, which can reduce the amount of calculation required for comparison and improve the efficiency of spot inspections to a certain extent.

[0016] In some embodiments, the host computer is configured to determine spot inspection parameters based on the inspection image and determine hardware spot inspection results based on the spot inspection parameters. The spot inspection parameters include the grayscale value of irregularly shaped color blocks and the radius of circular color blocks in the inspection image. Thus, the host computer is capable of identifying two types of spot inspection parameters: grayscale value and radius value in the film inspection image. It establishes a correspondence between preset values ​​and detection values ​​within multiple rectangular regions, thereby enabling spot inspection of the reliability of the tab ultrasonic welding inspection system's grayscale value recognition and size recognition.

[0017] In some embodiments, the host computer is further configured to determine a tab defect detection result based on a preset tab state image, and to determine a software spot inspection result based on the tab defect detection result and a preset defect result corresponding to the preset tab state image. Thus, by identifying a tab state image having a preset defect, the host computer's software spot inspection result can be determined based on the tab defect detection result and the preset defect result.

[0018] In some embodiments, the tab ultrasonic welding detection system further includes a lower computer and a clamp. The upper computer is further configured to transmit the hardware inspection results to the manufacturing execution system. In response to a passing hardware inspection result, the upper computer transmits the hardware inspection results to the lower computer, which controls the clamp to remove the calibration block. Thus, the hardware inspection results are transmitted to the manufacturing execution system, which obtains the hardware inspection results of the tab ultrasonic welding detection system, allowing operators to obtain the reliability status of the tab ultrasonic welding detection system in real time in the manufacturing execution system. When the hardware inspection result passes, the lower computer controls the clamp to remove the calibration block from the tab ultrasonic welding detection system, which helps to improve the automation level of the inspection process and enhance production efficiency.

[0019] An embodiment of the second aspect of the present application provides a spot inspection method for a tab ultrasonic welding detection system, which is performed within the tab ultrasonic welding detection system provided by the first aspect of the present application. The spot inspection method includes acquiring inspection images of a first film sheet and a second film sheet; determining spot inspection judgment parameters based on the inspection images; determining hardware spot inspection results for a first camera, a second camera, a first bar light source, and a second bar light source based on the spot inspection judgment parameters; acquiring preset tab status images, the preset tab status images including at least one image of a tab with a predetermined defect and / or an image of a tab without a defect; determining defect detection results based on the preset tab status images; and determining software spot inspection results for visual inspection software within a host computer based on the defect detection results. Thus, by configuring a calibration block for the tab ultrasonic welding detection system and enabling the host computer to determine hardware and software spot inspection results, the reliability of the detection system can be inspected, facilitating timely detection of abnormal conditions in the tab ultrasonic welding detection system, thereby preventing the tab ultrasonic welding detection system from operating in a low-reliability state and resulting in the outflow of a large number of defective products. Since the host computer is configured to perform inspections at the hardware and software levels respectively and determine the hardware inspection results and software inspection results, the hardware or software of the equipment can be debugged in a targeted manner, which is conducive to shortening the debugging time of the detection system and thereby improving the overall efficiency of the tab ultrasonic welding process to a certain extent.

[0020] In some embodiments, the first and second film sheets each include multiple rectangular areas, each rectangular area including a circular color block and a shaped color block surrounding the circular color block. The radii of the multiple circular color blocks differ, and the grayscale values ​​of the multiple shaped color blocks differ. Furthermore, the inspection judgment parameters include the grayscale values ​​of the shaped color blocks and the radius values ​​of the circular color blocks in the inspection image. Thus, the presence of at least two shaped color blocks with different grayscale values ​​and two circular color blocks with different radii not only provides different grayscale values ​​and radii for detection and identification by the tab ultrasonic welding inspection system, reducing the risk of false detection of a single inspection target and providing foolproof inspection, but also allows the detection capability and accuracy of the tab ultrasonic welding inspection system to be tested from different perspectives by identifying the differences between different grayscale values ​​in the image and comparing them with the corresponding grayscale value differences on the film sheet, or by identifying the differences between different radii in the image and comparing them with the corresponding radii differences on the film sheet, thereby improving the reliability of the hardware inspection results of the tab ultrasonic welding inspection system.

[0021] In some embodiments, determining the hardware spot inspection results for the first camera, the second camera, the first bar light source, and the second bar light source based on the spot inspection judgment parameters includes: comparing the spot inspection judgment parameters with corresponding preset characteristic parameters, where the preset characteristic parameters include the grayscale value of the irregular color block and the radius of the circular color block; and determining the hardware spot inspection result as failed in response to the difference between the spot inspection judgment parameter and the corresponding preset characteristic parameter exceeding a preset range. Thus, by setting a preset range and determining whether the difference between the spot inspection judgment parameter and the corresponding preset characteristic parameter exceeds the preset range, automatic inspection of the tab ultrasonic welding detection system can be achieved, and the hardware spot inspection results of the tab ultrasonic welding detection system can be determined more accurately, thereby improving the efficiency of spot inspection to a certain extent.

[0022] In some embodiments, determining the hardware spot inspection results for the first camera, the second camera, the first bar light source, and the second bar light source based on the spot inspection judgment parameters further includes determining the hardware spot inspection result as failed in response to the difference between the grayscale values ​​of any two irregularly shaped color blocks and the grayscale value difference in the corresponding preset characteristic parameters exceeding a grayscale threshold range. Thus, by setting the grayscale threshold range, it is possible to more accurately determine whether the grayscale value recognition capability of the tab ultrasonic welding inspection system is normal.

[0023] In some embodiments, determining the hardware inspection results for the first camera, the second camera, the first bar light source, and the second bar light source based on the inspection judgment parameters further includes determining the hardware inspection result as failed in response to a deviation between the detected radius of any circular color block and the radius in the corresponding preset characteristic parameter exceeding a size threshold range. Thus, by setting the size threshold range, the dimensional recognition capability of the tab ultrasonic weld inspection system can be more accurately determined.

[0024] In some embodiments, determining the software inspection result of the visual inspection software in the host computer based on the defect detection result includes: comparing the defect detection result with a preset defect result corresponding to a preset tab state image; and in response to the defect detection result being inconsistent with the preset defect result, determining the software inspection result of the visual inspection software in the host computer as a failure. Thus, by identifying the tab state image with the preset defect, the software inspection result of the host computer can be determined based on the tab defect detection result and the preset defect result, thereby improving the comprehensiveness and accuracy of the tab ultrasonic welding inspection system inspection.

[0025] In some embodiments, in response to a hardware inspection failure, adjustments are made to the first camera, the second camera, the first bar light source, and the second bar light source; and / or in response to a software inspection failure, software debugging is performed on the host computer of the tab ultrasonic weld detection system. This allows for maintenance of the tab ultrasonic weld detection system, thereby improving production efficiency.

[0026] In some embodiments, the tab ultrasonic welding detection system further includes a slave computer and a clamping jaw, and the inspection method further includes transmitting the hardware inspection result to a manufacturing execution system; in response to a passing hardware inspection result, the hardware inspection result is transmitted to the slave computer, and the slave computer controls the clamping jaw to remove the calibration block. Thus, the hardware inspection result is transmitted to the manufacturing execution system, and the manufacturing execution system obtains the reliability status of the tab ultrasonic welding detection system, thereby allowing operators to obtain real-time hardware reliability information from the manufacturing execution system. When the hardware inspection result passes, the slave computer controls the clamping jaw to remove the calibration block from the tab ultrasonic welding detection system, thereby increasing the automation level of the inspection process and improving production efficiency.

[0027] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In the accompanying drawings, unless otherwise specified, the same reference numerals throughout the multiple drawings represent the same or similar components or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings only depict some embodiments disclosed in this application and should not be construed as limiting the scope of this application.

[0029] FIG1 is a schematic diagram of a tab ultrasonic welding detection system according to some embodiments of the present application;

[0030] FIG2 is a schematic diagram of a calibration block according to some embodiments of the present application;

[0031] FIG3 is a schematic diagram of a first film according to some embodiments of the present application;

[0032] FIG4 is a schematic diagram of a first film according to some other embodiments of the present application;

[0033] FIG5 is a flow chart of a spot inspection method of a tab ultrasonic welding detection system according to some embodiments of the present application;

[0034] FIG6 is a schematic diagram of the connection relationship between the host computer, the manufacturing execution system, and the slave computer in some embodiments of the present application.

[0035] Description of reference numerals:

[0036] Tab ultrasonic welding detection system 1; calibration block 2; first battery contour 21; second battery contour 22; first tab contour 23; second tab contour 24; groove 25; first camera 31; second camera 32; first bar light source 41; second bar light source 42; host computer 5; slave computer 6; gripper 7; manufacturing execution system (MES) 8;

[0037] A first film 101; a second film 102;

[0038] Rectangular area 10; first rectangular area 11; second rectangular area 12; third rectangular area 13; fourth rectangular area 14;

[0039] Circular color block 120; first circular color block 121; second circular color block 122; third circular color block 123; fourth circular color block 124;

[0040] Irregular color block 110; first irregular color block 111; second irregular color block 112; third irregular color block 113; fourth irregular color block 114; cut-off angle 130;

[0041] A first direction D1, a second direction D2, a first preset path P1, and a second preset path P2. DETAILED DESCRIPTION

[0042] The following embodiments of the technical solution of the present application will be described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application and are therefore only examples and are not intended to limit the scope of protection of the present application.

[0043] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" and any variations thereof in the specification and claims of this application and the above-mentioned figure descriptions are intended to cover non-exclusive inclusions.

[0044] In the description of the embodiments of this application, the technical terms "first" and "second" are used only to distinguish different objects and should not be understood to indicate or imply relative importance or implicitly specify the quantity, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, the meaning of "plurality" is more than two, unless otherwise clearly and specifically defined.

[0045] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0046] In the description of the embodiments of this application, the term "and / or" is simply a description of the association relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can represent the following three situations: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " in this document generally indicates that the associated objects are in an "or" relationship.

[0047] In the description of the embodiments of the present application, the term "multiple" refers to more than two (including two). Similarly, "multiple groups" refers to more than two groups (including two groups), and "multiple pieces" refers to more than two pieces (including two pieces).

[0048] In the description of the embodiments of the present application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the embodiments of the present application.

[0049] In the description of the embodiments of the present application, unless otherwise expressly specified or limited, technical terms such as "installed," "connected," "connected," and "fixed" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; internal connections between two components or interactions between two components. Those skilled in the art can understand the specific meanings of the above terms in the embodiments of the present application based on specific circumstances.

[0050] There may be certain defects in the battery production process, and various detection methods are needed to detect the defects in order to improve the battery yield. In the related art, a tab ultrasonic welding detection system is used to detect the quality of the battery during the production process. The tab ultrasonic welding detection system needs to be calibrated during the initial installation so that the detection accuracy of the tab ultrasonic welding detection system can meet the detection requirements. In some cases, the reliability of the tab ultrasonic welding detection system may change with changes in production conditions or equipment changes. In order to prevent the tab ultrasonic welding detection system from failing and causing defective products to flow out, it is necessary to conduct a spot check on the reliability of the tab ultrasonic welding detection system. In some embodiments, during the ultrasonic tab welding process, the tab ultrasonic welding detection system is used to detect defects in the tab area, but there is a lack of spot checks on the reliability of the tab ultrasonic welding detection system itself.

[0051] To this end, an embodiment of the present application provides a tab ultrasonic welding detection system capable of performing spot checks on its own reliability. The system includes a calibration block, a first camera, a second camera, a first bar light source, a second bar light source, and a host computer. The calibration block includes a first battery shaped body, a second battery shaped body, a first tab shaped body, a second tab shaped body, a first film sheet, and a second film sheet. The first battery shaped body is connected to the second battery shaped body via the first tab shaped body and the second tab shaped body. The first film sheet is attached to the surface of the first tab shaped body, and the second film sheet is attached to the surface of the second tab shaped body. The host computer determines the hardware spot check results of the tab ultrasonic welding detection system using detection images of the first and second films captured by the first and second cameras, respectively, and determines the software spot check results of the visual inspection software within the host computer based on preset tab status images.

[0052] During spot inspections of the tab ultrasonic welding inspection system, the system's grayscale recognition capability can be tested by acquiring and comparing the grayscale values ​​of irregularly shaped color blocks in each rectangular area of ​​the inspection image. The system's size recognition capability can be tested by acquiring and comparing the radius values ​​of circular color blocks in each rectangular area of ​​the inspection image. The hardware inspection results of the tab ultrasonic welding inspection system can be determined based on the comparison results. Simultaneously, the software inspection results of the visual inspection software in the host computer can be determined by inspecting a preset image with a set defect and obtaining the inspection results of the preset image.

[0053] FIG1 is a schematic diagram of a tab ultrasonic welding detection system 1 according to some embodiments of the present application.

[0054] As shown in FIG1 , the tab ultrasonic welding detection system 1 includes a calibration block 2 , a first camera 31 , a second camera 32 , a first strip light source 41 , a second strip light source 42 and a host computer 5 .

[0055] The calibration block 2 includes a first battery profiling body 21, a second battery profiling body 22, a first tab profiling body 23, a second tab profiling body 24, a first film 101, and a second film 102. The first battery profiling body 21 is connected to the second battery profiling body 22 via the first tab profiling body 23 and the second tab profiling body 24. The first film 101 is attached to the surface of the first tab profiling body 23, and the second film 102 is attached to the surface of the second tab profiling body 24.

[0056] The first camera 31 and the second camera 32 are arranged along the first direction D1 and are respectively located directly above the first tab contour 23 and the second tab contour 24; the first camera 31 is used to capture a detection image of the first film 101, and the second camera 32 is used to capture a detection image of the second film 102;

[0057] The first bar light source 41 and the second bar light source 42 are respectively located on both sides of the first camera 31 and the second camera 32 along the second direction D2, the second direction D2 is perpendicular to the first direction D1, and the first bar light source 41 and the second bar light source 42 are both configured to simultaneously illuminate the first tab contour 23 and the second tab contour 24.

[0058] The host computer 5 is configured to determine hardware inspection results of the first camera 31, the second camera 32, the first bar light source 41, and the second bar light source 42 based on the inspection images captured by the first camera 31 and the second camera 32. The host computer 5 is also configured to determine software inspection results of the visual inspection software within the host computer 5 based on the preset tab status images.

[0059] As shown in Figure 1, the dimensions of the calibration block 2 can be designed to mimic the dimensions of the paired battery cells to be inspected. Specifically, the calibration block 2 includes a first battery profiling body 21, a second battery profiling body 22, a first tab profiling body 23, and a second tab profiling body 24, modeled after the structure of paired battery cells after tab welding. By attaching the first film 101 and the second film 102 to the surfaces of the first tab profiling body 23 and the second tab profiling body 24, respectively, the calibration block 2 can better simulate the actual inspection object of the tab ultrasonic welding detection system 1, ensuring that the inspection image obtained during the spot inspection is as consistent as possible with the inspection image during the actual inspection, thereby improving the accuracy of the spot inspection results.

[0060] The first camera 31 and the second camera 32 are imaging units for respectively acquiring inspection images of the first film sheet 101 and the second film sheet 102. The first camera 31 and the second camera 32 are spaced apart along the first direction D1 and are respectively located directly above the first tab contour 23 and the second tab contour 24. In some examples, the first camera 31 and the second camera 32 may be CCD cameras, thereby providing high-definition inspection images.

[0061] The first and second bar-shaped light sources 41, 42 simultaneously illuminate the first and second tab profiles 23, 24, thereby facilitating imaging by the first and second cameras 31, 32. The first and second bar-shaped light sources 41, 42 are located on either side of the first and second cameras 31, 32, respectively, in the second direction D2 and extend along the first direction D1. The first and second bar-shaped light sources 41, 42 face each other and illuminate the first and second tab profiles 23, 24 in an obliquely downward direction.

[0062] The host computer 5 can be connected to at least the first camera 31 and the second camera 32 by signal and can be configured with visual inspection software, which is used to identify and process the inspection images collected by the first camera 31 and the second camera 32, identify the defective parts and defect types in the inspection images, and reduce the risk of defective battery cells flowing out. It is understandable that when the working state of the camera or light source changes, the inspection image received by the host computer 5 may change accordingly. For example, the relevant parameters in the inspection image (such as grayscale value, pixel size, etc.) change, which may cause the host computer 5 to have a large deviation in the recognition result of the inspection image, thereby affecting the reliability of the ultrasonic welding inspection of the tab.

[0063] The host computer 5 may also be configured to determine hardware inspection results of the first camera 31, the second camera 32, the first bar light source 41, and the second bar light source 42 based on the inspection images captured by the first camera 31 and the second camera 32. Visual inspection software may be installed in the host computer 5, and the host computer 5 may be further configured to determine software inspection results of the visual inspection software in the host computer 5 based on a preset tab status image.

[0064] Thus, by configuring the tab ultrasonic welding detection system 1 with a calibration block 2 and enabling the host computer 5 to determine the hardware inspection results and software inspection results, the reliability of the detection system itself can be inspected, which is conducive to timely detection of abnormal conditions of the tab ultrasonic welding detection system 1, thereby preventing the tab ultrasonic welding detection system 1 from operating in a low reliability state and causing a large number of defective products to be discharged. Because the host computer 5 is configured to perform inspections at the hardware level and software level respectively, and to determine the hardware inspection results and software inspection results respectively, the hardware or software of the system can be debugged in a targeted manner, which is conducive to shortening the debugging time of the detection system and, to a certain extent, improving the overall efficiency of the tab ultrasonic welding process.

[0065] FIG2 is a schematic diagram of a calibration block 2 according to some embodiments of the present application.

[0066] As shown in Figures 1 and 2, the surfaces of the first tab shaped body 23 and the second tab shaped body 24 facing the first camera 31 and the second camera 32 are respectively provided with grooves 25, and the grooves 25 are used to accommodate the first film 101 and the second film 102, so that the upper surfaces of the first film 101 and the second film 102 are flush with the surfaces of the first tab shaped body 23 and the second tab shaped body 24.

[0067] The groove 25 is formed by the first tab profiling body 23 and the second tab profiling body 24 being concave from the surface. The depth of the groove 25 can be the same as the thickness of the first film 101 and the second film 102. The projection size of the groove 25 can be equal to the projection size of the first film 101 and the second film 102.

[0068] Therefore, after the first film sheet 101 and the second film sheet 102 are respectively attached, the first tab shaped body 23 and the second tab shaped body 24 can simulate the actual flat tab surface, and can also reduce the error caused by the difference in height between the film surface and the actual tab to a certain extent, thereby helping to ensure that the hardware inspection results are consistent with the actual tab welding inspection to a certain extent.

[0069] FIG3 is a schematic diagram of the first film 101 according to some embodiments of the present application.

[0070] As shown in FIG3 , the first film 101 includes a plurality of rectangular areas 10 , each rectangular area 10 includes a circular color block 120 and a heteromorphic color block 110 surrounding the circular color block 120 , the radii of the plurality of circular color blocks 120 are different, and the grayscale values ​​of the plurality of heteromorphic color blocks 110 are different.

[0071] As shown in FIG3 , the first film 101 may include four rectangular areas 10, namely a first rectangular area 11, a second rectangular area 12, a third rectangular area 13, and a fourth rectangular area 14. Each rectangular area 10 may include a non-uniform color block 110 and a circular color block 120. In each rectangular area 10, the circular color block 120 is located inside the non-uniform color block 110, and the grayscale value of the circular color block 120 is different from that of the non-uniform color block 110, so as to facilitate identification and distinction.

[0072] In some embodiments, the rectangular regions 10 in the first film 101 are each grayscale. This allows the inspection images captured by the tab ultrasonic welding inspection system 1 during spot inspection to also be grayscale images, facilitating the determination of the grayscale values ​​of the corresponding regions. The grayscale values ​​of the irregularly shaped color blocks 110 and the circular color blocks 120 can range from 0 to 255, with white being 255 and black being 0. Grayscale value detection can be achieved through hardware-based or non-hardware-based detection methods. For example, a sensor or other device can be installed to directly measure the target region of the film to obtain the grayscale value of the corresponding region.

[0073] This application does not impose any specific restrictions on the number of rectangular areas 10. However, it is understood that a greater number of rectangular areas 10 means that the surface of the first film 101 is discretized into a greater number of inspection areas, and the tab ultrasonic welding detection system can compare more inspection areas (specifically, the grayscale values ​​of the irregularly shaped color blocks 110 and the radius of the circular color blocks 120). This results in a higher degree of accuracy in the spot inspection results of the tab ultrasonic welding detection system 1. In some embodiments, when determining the number of rectangular areas 10 of the first film 101, a specific setting can be made based on the accuracy requirements of the spot inspection, thereby improving the accuracy of the spot inspection results.

[0074] Among the multiple irregularly shaped color blocks 110, at least two irregularly shaped color blocks 110 have different grayscale values, thereby verifying the ability of the tab ultrasonic welding detection system 1 to recognize different grayscale values. In some embodiments, the grayscale values ​​of the multiple irregularly shaped color blocks 110 are all different. As shown in Figure 3, the grayscale value of each irregularly shaped color block 110 in the four rectangular areas 10 of the first film 101 is different. Specifically, the grayscale value of the first irregularly shaped color block 111 in the first rectangular area 11 is 220, the grayscale value of the second irregularly shaped color block 112 in the second rectangular area 12 is 160, the grayscale value of the third irregularly shaped color block 113 in the third rectangular area 13 is 100, and the grayscale value of the fourth irregularly shaped color block 114 in the fourth rectangular area 14 is 40.

[0075] At least two of the multiple circular color blocks 120 have different radii, thereby verifying the ability of the tab ultrasonic welding detection system 1 to recognize different lengths. In some embodiments, the radius values ​​of the multiple circular color blocks 120 are different. As shown in Figure 3, the grayscale value of each circular color block 120 in the four rectangular areas 10 of the first film 101 is different. Among them, the radius of the first circular color block 121 in the first rectangular area 11 is 2.0 millimeters (mm), the radius of the second circular color block 122 in the second rectangular area 12 is 1.5 millimeters (mm), the radius of the third circular color block 123 in the third rectangular area 13 is 1.0 millimeters (mm), and the radius of the fourth circular color block 124 in the fourth rectangular area 14 is 0.5 millimeters (mm).

[0076] It should be noted that the second film 102 can be arranged in the same manner as the first film 101 , and thus the arrangement method of the second film 102 will not be described in detail in this application.

[0077] Therefore, since there are at least two irregular color blocks 110 with different grayscale values ​​and two circular color blocks 120 with different radii, this not only can provide different grayscale values ​​and radii for the tab ultrasonic welding detection system 1 to detect and identify, reducing the risk of false detection of a single detection target and playing a role in fool-proof inspection, but also can identify the difference between different grayscale values ​​in the detection image and compare it with the difference between the corresponding grayscale values ​​on the film, or identify the difference between different radii in the detection image and compare it with the difference between the corresponding radii on the film, the detection capability and detection accuracy of the tab ultrasonic welding detection system 1 can be tested from different angles, thereby improving the reliability of the hardware inspection results of the tab ultrasonic welding detection system 1.

[0078] FIG4 is a schematic diagram of the first film 101 according to some other embodiments of the present application.

[0079] As shown in Figure 4, along the first preset path P1 that passes through each rectangular area 10 in sequence, the grayscale value of the irregular color block 110 gradually increases; the smallest radius of the multiple circular color blocks 120 is greater than or equal to the minimum detection size of the first camera 31 and the second camera 32, and along the second preset path P2 that passes through each rectangular area 10 in sequence, the radius of the circular color block 120 decreases by an integer multiple of the minimum detection size.

[0080] The first preset path P1 may be any pre-set path that passes through each rectangular area 10 in sequence. Along the first preset path P1, the grayscale values ​​of the multiple irregular color blocks 110 corresponding to the multiple rectangular areas 10 change regularly, for example, gradually increase or decrease.

[0081] Referring to Figure 4, in some embodiments, a first preset path P1 can be defined on the first film 101, along which the grayscale values ​​of the multiple irregularly shaped color blocks gradually increase or decrease. Thus, the tab ultrasonic welding detection system 1 can sequentially acquire the grayscale values ​​of the irregularly shaped color blocks 110 in each rectangular area 10 along the first preset path P1. If the grayscale values ​​of the preceding and following irregularly shaped color blocks 110 acquired by the tab ultrasonic welding detection system 1 along the first preset path P1 do not conform to the preset variation pattern, the tab ultrasonic welding detection system 1 can be deemed unreliable, and further grayscale detection or comparison of subsequent irregularly shaped color blocks along the first preset path P1 is unnecessary. This can, to a certain extent, reduce the computational complexity of the tab ultrasonic welding detection system 1 during spot inspections, thereby improving spot inspection efficiency.

[0082] In some embodiments, the grayscale values ​​of multiple irregular color blocks 110 can change in an arithmetical manner along the first preset path P1. Under the arithmetical change manner, the grayscale values ​​of the irregular color blocks 110 are evenly distributed within a given grayscale value range, and the detection is more comprehensive. To a certain extent, it avoids the problem of being unable to identify the insufficient reliability of the tab ultrasonic welding detection system 1 within certain possible grayscale value ranges, thereby improving the accuracy of the reliability test to a certain extent.

[0083] Similarly, referring to FIG. 4 , a second preset path P2 can be defined on the first film 101, along which the radii of the plurality of circular color blocks 120 gradually decrease. Thus, the tab ultrasonic welding detection system 1 can sequentially obtain the radius of the circular color blocks 120 in each rectangular area 10 along the second preset path P2. If the radii of the two preceding and succeeding circular color blocks 120 obtained by the tab ultrasonic welding detection system 1 along the second preset path P2 do not conform to the preset variation pattern, the tab ultrasonic welding detection system 1 can be deemed to be insufficiently reliable, and further detection or comparison of the radii of subsequent circular color blocks 120 along the second preset path P2 is unnecessary. This can, to a certain extent, reduce the computational complexity of the tab ultrasonic welding detection system 1 during spot inspections, thereby improving spot inspection efficiency.

[0084] It is understandable that due to the limited resolution of the first camera 31 and the second camera 32, if the radius on the first film 101 is smaller than the minimum detection size of the first camera 31 and the second camera 32, the radius cannot be accurately presented in the collected detection image, which is not conducive to subsequent image recognition. Therefore, with reference to the minimum detection size of the first camera 31 and the second camera 32 in the tab ultrasonic welding detection system 1, the radius of the multiple circular color blocks 120 on the first film 101 can be set to be greater than or equal to the minimum detection size, thereby ensuring that the obtained detection images can be used to determine whether the size recognition capability of the tab ultrasonic welding detection system 1 meets the reliability requirements.

[0085] Therefore, through the above two preset paths, the grayscale value of the irregular color block 110 and the radius of the circular color block 120 both increase or decrease along the path, so that the tab ultrasonic welding detection system 1 can reduce the amount of calculation during comparison to a certain extent, thereby improving the efficiency of spot inspection to a certain extent, by comparing the grayscale value and radius obtained during spot inspection to see whether they meet the preset change rules.

[0086] According to some embodiments of the present application, the host computer 5 may be further configured to determine spot inspection judgment parameters based on the detection image, and determine the hardware spot inspection result based on the spot inspection judgment parameters. The spot inspection judgment parameters include the grayscale value of the irregular color block 110 and the radius of the circular color block 120 in the detection image.

[0087] After obtaining the detection images of the first film 101 and the second film 102, and based on the detection images, the spot inspection judgment parameters can be specifically determined as the detection values ​​of the grayscale values ​​of multiple special-shaped color blocks 110 and the detection values ​​of the radius of multiple circular color blocks 120. In this way, a correspondence between the preset values ​​and the detection values ​​is established in multiple rectangular areas 10, and the tab ultrasonic welding detection system 1 can be inspected in multiple rectangular areas 10.

[0088] Therefore, the host computer 5 has the ability to identify the two types of spot inspection judgment parameters, namely the grayscale detection value and the radius detection value, in the detection image of the film, and establishes a correspondence between the preset value and the detection value in multiple rectangular areas 10, so that the reliability of the grayscale value recognition and size recognition of the tab ultrasonic welding detection system 1 can be inspected.

[0089] According to some embodiments of the present application, the host computer 5 can also be configured to determine the tab defect detection result based on the preset tab status image, and determine the software inspection result based on the tab defect detection result and the preset defect result corresponding to the preset tab status image.

[0090] The preset tab state image may be an image stored in advance in an image library in a storage device, and the storage device may be a memory of the host computer 5 or a memory located in the cloud. The preset tab state image may include an image of a tab with a set defect and / or an image of a tab without defects. The image of a tab with a set defect means that the tab of the battery cell in the image has one or more specific defect types, and the image of a tab without defects means that the tab of the battery cell in the image has no defects. Each preset tab state image has been identified in advance and the corresponding preset result is stored. In some embodiments, obtaining the preset tab state image may be by randomly extracting any one or more preset images from the image library, or by traversing each preset image in the image library for subsequent defect detection.

[0091] The host computer 5 is equipped with visual inspection software, and the preset tab state image is inspected by the visual inspection software, so as to determine the defect detection result of the image, and determine the software inspection result of the visual inspection software in the host computer 5 according to the defect detection result.

[0092] Therefore, by identifying the tab state image with the preset defect, the software inspection result of the host computer 5 can be determined according to the tab defect detection result and the preset defect result.

[0093] According to some embodiments of the present application, the tab ultrasonic welding detection system 1 also includes a lower computer 6 and a clamp 7. The upper computer 5 is also configured to send the hardware inspection result to the manufacturing execution system (MES) 8, and in response to the hardware inspection result being passed, the upper computer 5 sends the hardware inspection result to the lower computer 6, and the lower computer 6 controls the clamp 7 to remove the calibration block 2.

[0094] A Manufacturing Execution System (MES) 8 is a shop-floor management information system that sits between the upper-level planning and management systems and the lower-level production equipment. It improves factory floor efficiency and profitability. By collecting and analyzing production data in real time, the system optimizes production processes, reduces costs, and improves product quality. Key functions of an MES 8 include production scheduling, quality management, equipment management, and material management.

[0095] In some embodiments, the tab ultrasonic welding detection system 1 is electrically connected to the manufacturing execution system (MES) 8, and the tab ultrasonic welding detection system 1 can communicate with the manufacturing execution system (MES) 8 in real time. After the hardware inspection of the tab ultrasonic welding detection system 1 is completed, the host computer 5 sends the hardware inspection result to the manufacturing execution system (MES) 8, and the operator can understand the reliability status of the system in the manufacturing execution system (MES) 8. When the hardware inspection result is passed, the host computer 5 sends the hardware inspection result to the slave computer 6, and the slave computer 6 can control the clamp 7 to remove the calibration block 2, so that the battery cell product that has been ultrasonically welded can be placed under the first camera 31 and the second camera 32 for inspection. The aforementioned clamp 7 can be a manipulator of an automatic loading and unloading device, which can remove the calibration block 2 from the tab ultrasonic welding detection system 1 in response to the instruction of the slave computer 6.

[0096] Thus, the hardware inspection results are sent to the manufacturing execution system, which obtains the hardware inspection results of the tab ultrasonic welding detection system 1, so that the operator can obtain the reliability status of the tab ultrasonic welding detection system 1 in real time in the manufacturing execution system. If the hardware inspection result is passed, the host computer 5 sends the hardware inspection result to the slave computer 6, which controls the clamp 7 to remove the calibration block from the tab ultrasonic welding detection system 1, which helps to improve the automation level of the inspection process and improve production efficiency.

[0097] FIG5 is a flow chart of a spot inspection method 400 of a tab ultrasonic welding detection system according to some embodiments of the present application.

[0098] As shown in FIG5 , an embodiment of the second aspect of the present application provides a method 400 for inspecting a tab ultrasonic welding detection system, comprising:

[0099] Step 410 : Acquire detection images of the first film 101 and the second film 102 .

[0100] Step 420: Determine the inspection parameters based on the inspection image;

[0101] Step 430: Determine hardware inspection results of the first camera 31, the second camera 32, the first bar light source 41, and the second bar light source 42 according to the inspection judgment parameters;

[0102] Step 440: Acquire a preset tab state image, where the preset tab state image includes at least one image of a tab with a preset defect and / or an image of a tab without a defect.

[0103] Step 450: Determine a defect detection result according to a preset tab state image.

[0104] Step 460: Determine the software inspection result of the visual inspection software in the host computer 5 according to the defect detection result.

[0105] In step 410, the calibration block 2 is placed below the first camera 31 and the second camera 32, and the first film sheet 101 and the second film sheet 102 are aligned with the first camera 31 and the second camera 32, respectively. Inspection images of the first film sheet 101 and the second film sheet 102 are then acquired by the first camera 31 and the second camera 32, respectively. The shooting environment and parameters when acquiring the images can be consistent with the environment and parameters during actual inspection, thereby increasing the accuracy of the inspection.

[0106] In step 420, the acquired inspection image is provided to the host computer 5. The host computer 5 may be pre-programmed with corresponding image recognition software or programs to recognize the inspection image and determine the inspection parameters. The inspection parameters may include the grayscale value of the irregular color block 110 corresponding to the rectangular area, and the inspection parameters may also include the radius of the circular color block 120 corresponding to the rectangular area.

[0107] In step 430, the grayscale values ​​of the irregularly shaped color blocks 110 and the radius of the circular color blocks 120 corresponding to the respective preset rectangular regions of the first and second film sheets 101 and 102 can be input into the host computer 5 for storage. Specifically, these values ​​can be pre-entered based on the actual film sheets 101 and 102 to be used. The grayscale values ​​in the spot inspection judgment parameters are compared with the corresponding preset grayscale values, and the radius values ​​in the spot inspection judgment parameters are compared with the corresponding radius to determine the hardware spot inspection results for the first camera 31, the second camera 32, and the first and second strip light sources 41 and 42.

[0108] In step 440, the preset tab state image may be an image stored in advance in an image library in a storage device, and the storage device may be a memory of the host computer 5 or a memory located in the cloud. The preset tab state image may include an image of the tab with a set defect and / or an image of the tab without a defect. The image of the tab with a set defect means that the cell tab in the image has one or more specific defect types, and the image of the tab without a defect means that the cell tab in the image has no defects. Each preset tab state image has been identified in advance and the corresponding preset result is stored. In some embodiments, obtaining the preset tab state image may be by randomly extracting any one or more preset images from the image library, or by traversing each preset image in the image library for subsequent defect detection.

[0109] In steps 450 to 460, the host computer 5 is configured with visual inspection software, and the preset tab state image is inspected by the visual inspection software, so that the defect detection result of the image can be determined, and the software inspection result of the visual inspection software in the host computer 5 can be determined based on the defect detection result.

[0110] Therefore, by configuring the tab ultrasonic welding detection system 1 with a calibration block and enabling the host computer 5 to determine the hardware inspection results and software inspection results, the reliability of the detection system itself can be inspected, which is conducive to timely detection of abnormal conditions of the tab ultrasonic welding detection system 1, thereby preventing the tab ultrasonic welding detection system 1 from operating in a low reliability state, resulting in the outflow of a large number of defective products. Because the host computer 5 is configured to perform inspections and determine the hardware inspection results and software inspection results at the hardware and software levels respectively, the hardware or software of the device can be debugged in a targeted manner, which is conducive to shortening the debugging time of the detection system and, to a certain extent, improving the overall efficiency of the tab ultrasonic welding process.

[0111] According to some embodiments of the present application, a first film sheet 101 and a second film sheet 102 each include multiple rectangular areas 10, each rectangular area 10 including a circular color block 120 and a non-uniform color block 110 surrounding the circular color block 120. The radii of the multiple circular color blocks 120 are different, and the grayscale values ​​of the multiple non-uniform color blocks 110 are different. Furthermore, the spot inspection judgment parameters include the grayscale value of the non-uniform color block 110 and the radius of the circular color block 120 in the inspection image.

[0112] As shown in FIG3 , the first film 101 may include four rectangular areas 10, namely a first rectangular area 11, a second rectangular area 12, a third rectangular area 13, and a fourth rectangular area 14. Each rectangular area 10 may include a non-uniform color block 110 and a circular color block 120. In each rectangular area 10, the circular color block 120 is located inside the non-uniform color block 110, and the grayscale value of the circular color block 120 is different from that of the non-uniform color block 110, so as to facilitate identification and distinction.

[0113] By obtaining the detection images of the first film 101 and the second film 102 as described above, and based on the detection images, the spot inspection judgment parameters can be specifically determined as the detection value of the grayscale value of the irregular color block 110 and the detection value of the radius of the circular color block 120, so that a correspondence between the preset value and the detection value is established in multiple rectangular areas 10, and the tab ultrasonic welding detection system 1 can be inspected in multiple rectangular areas 10.

[0114] Therefore, since there are at least two irregular color blocks 110 with different grayscale values ​​and two circular color blocks 120 with different radii, this not only can provide different grayscale values ​​and radii for the tab ultrasonic welding detection system 1 to detect and identify, reducing the risk of false detection of a single detection target and playing a role in fool-proof inspection, but also can identify the difference between different grayscale values ​​in the image and compare it with the difference between the corresponding grayscale values ​​on the film, or identify the difference between different radii in the image and compare it with the difference between the corresponding radii on the film, the detection capability and detection accuracy of the tab ultrasonic welding detection system can be tested from different angles, thereby improving the reliability of the hardware inspection results of the tab ultrasonic welding detection system.

[0115] According to some embodiments of the present application, determining hardware spot inspection results of the first camera 31 , the second camera 32 , the first bar light source 41 , and the second bar light source 42 based on the spot inspection judgment parameters includes:

[0116] Comparing the inspection judgment parameter with the corresponding preset characteristic parameters, wherein the preset characteristic parameters include the grayscale value of the irregular color block 110 and the radius of the circular color block 120;

[0117] In response to a difference between the spot inspection determination parameter and the corresponding preset characteristic parameter exceeding a preset range, the hardware spot inspection result is determined to be failed.

[0118] The preset range may include a grayscale threshold range and a length threshold range. The grayscale threshold range and the length threshold range are both determined based on the recognition capability of the tab ultrasonic welding detection system and the defect type of the detection target, and are used to measure the reliability of the grayscale value recognition and size recognition of the tab ultrasonic welding detection system.

[0119] After acquiring images of the first film sheet 101 and the second film sheet 102 , the reliability of the tab ultrasonic welding detection system 1 can be judged from the accuracy of grayscale value recognition, or from the accuracy of size recognition.

[0120] For example, in some embodiments, the grayscale value of the image of the irregularly shaped color block 110 in any rectangular area 10 in the preset feature parameters can be compared with the grayscale value of the corresponding irregularly shaped color block 110 in the spot inspection judgment parameters to calculate whether the difference ΔT1 between the two exceeds a preset grayscale threshold range. For example, the grayscale threshold range can be between -5 and 5. If the calculated difference ΔT1 satisfies -5≤ΔT1≤5, then the tab ultrasonic welding detection system 1 is determined to have met the grayscale value recognition requirements and good reliability, and the hardware spot inspection result can be considered to have passed. Otherwise, the tab ultrasonic welding detection system is determined to have failed the grayscale value recognition requirements and poor reliability, and the hardware spot inspection result can be considered to have failed.

[0121] Therefore, by setting a preset range and judging whether the difference between the inspection parameter and the corresponding preset characteristic parameter exceeds the preset range, the automatic inspection of the tab ultrasonic welding detection system 1 can be achieved, and the hardware inspection results of the tab ultrasonic welding detection system 1 can be judged more accurately, thereby improving the efficiency of the inspection to a certain extent.

[0122] According to some embodiments of the present application, determining hardware spot inspection results of the first camera 31 , the second camera 32 , the first bar light source 41 , and the second bar light source 42 based on the spot inspection judgment parameters further includes:

[0123] In response to the deviation between the difference between the grayscale values ​​of any two irregularly shaped color blocks 110 and the grayscale value difference in the corresponding preset characteristic parameters exceeding the grayscale threshold range, the hardware inspection result is determined to be failed.

[0124] In some embodiments, the difference in the image grayscale values ​​of any two irregularly shaped color blocks 110 in the preset characteristic parameters can be compared with the difference in the corresponding two grayscale values ​​in the spot inspection judgment parameters to calculate whether the difference ΔT2 between the two exceeds the preset grayscale threshold range, that is, whether it satisfies -5≤ΔT2≤5. If so, the tab ultrasonic welding detection system 1 is determined to have met the grayscale value recognition requirements and good reliability, and the hardware spot inspection result can be considered a pass. Otherwise, the tab ultrasonic welding detection system 1 is determined to have failed the grayscale value recognition requirements and poor reliability, and the hardware spot inspection result can be considered a fail.

[0125] Therefore, by setting the grayscale threshold range, it is possible to more accurately determine whether the grayscale value recognition capability of the tab ultrasonic welding detection system 1 is normal.

[0126] According to some embodiments of the present application, the hardware spot inspection results of the first camera 31, the second camera 32, the first bar light source 41, and the second bar light source 42 determined based on the spot inspection judgment parameters further include:

[0127] In response to a deviation between the detected value of the radius of any circular color block 120 and the radius in the corresponding preset characteristic parameter exceeding a size threshold range, the hardware inspection result is determined to be failed.

[0128] In some embodiments, the size threshold range can be determined based on the size tolerance of the circular color block 120 in the first film 101 or the second film 102. For example, the radius tolerance of the circular color block 120 in the first film 101 is The size threshold range can be less than or equal to or Specifically, it can be determined according to the detection accuracy requirements of the camera. The image radius of any circular color block 120 in the image feature parameter can be calculated by difference calculation with the corresponding radius value in the preset feature parameter, and the difference △T3 between the two is calculated to see whether it exceeds the preset size threshold range, that is, whether it meets the requirements. If so, the tab ultrasonic welding detection system's dimensional recognition capability meets the requirements, its reliability is good, and the hardware inspection result is considered passed. Otherwise, the tab ultrasonic welding detection system's dimensional recognition capability does not meet the requirements, its reliability is poor, and the hardware inspection result is considered failed.

[0129] Therefore, by setting the size threshold range, it is possible to more accurately determine whether the size recognition capability of the tab ultrasonic welding detection system is normal.

[0130] According to some embodiments of the present application, determining the software spot inspection result of the visual inspection software in the host computer 5 based on the defect detection result includes: comparing the defect detection result with the preset defect result corresponding to the preset tab state image, and in response to the defect detection result being inconsistent with the preset defect result, determining the software spot inspection result of the visual inspection software in the host computer 5 as failed.

[0131] In some embodiments, if the defect detection result of the preset tab state image is consistent with the preset result, it indicates that the visual inspection software of the tab ultrasonic welding detection system 1 is operating normally, and the software inspection result of the tab ultrasonic welding detection system 1 passes. If it is inconsistent, it indicates that the visual inspection software of the tab ultrasonic welding detection system 1 may have an algorithm mutation or algorithm failure, and the software inspection result of the tab ultrasonic welding detection system 1 fails. The tab ultrasonic welding detection system 1 needs to be debugged and re-inspected after debugging is completed until the software inspection result passes.

[0132] Therefore, by identifying the tab state image with preset defects, the software inspection result of the host computer 5 can be determined according to the tab defect detection result and the preset defect result, thereby improving the comprehensiveness and accuracy of the tab ultrasonic welding detection system 1 inspection.

[0133] According to some embodiments of the present application, in response to a hardware inspection result of failing, the first camera 31, the second camera 32, the first strip light source 41 and the second strip light source 42 are adjusted; and / or in response to a software inspection result of failing, the upper computer 5 of the tab ultrasonic welding detection system 1 is software debugged.

[0134] Therefore, the tab ultrasonic welding detection system 1 can be inspected and repaired, which is beneficial to improving production efficiency.

[0135] According to some embodiments of the present application, the hardware inspection result is sent to the manufacturing execution system; in response to the hardware inspection result being passed, the hardware inspection result is sent to the lower computer 6, and the lower computer 6 controls the clamp 7 to remove the calibration block 2.

[0136] Thus, the hardware inspection results are sent to the manufacturing execution system, which obtains the reliability status of the tab ultrasonic welding detection system 1, so that the operator can obtain the hardware reliability of the tab ultrasonic welding detection system 1 in real time in the manufacturing execution system. When the hardware inspection result is passed, the hardware inspection result is sent to the slave computer 6, and the slave computer 6 controls the clamp 7 to remove the calibration block from the tab ultrasonic welding detection system 1, which helps to improve the automation level of the inspection process and improve production efficiency.

[0137] The technical solution of this application is further illustrated below through some specific embodiments.

[0138] As shown in Figures 1 to 3, the first film 101 may include four rectangular areas 10, namely a first rectangular area 11, a second rectangular area 12, a third rectangular area 13, and a fourth rectangular area 14. Each rectangular area 10 includes a non-uniform color block 110 and a circular color block 120. In each rectangular area 10, the circular color block 120 is located inside the non-uniform color block 110, and the grayscale value of the circular color block 120 is different from that of the non-uniform color block 110. It should be noted that the second film 102 can be the same as the first film 101, and therefore the second film 102 is not described here in detail.

[0139] The first rectangular area 11, the second rectangular area 12, the third rectangular area 13 and the fourth rectangular area 14 are arranged in a 2×2 array. Along the first preset path of the "Z" shape, the grayscale values ​​of the irregular color blocks 110 in the four rectangular areas are 220, 160, 100 and 40 respectively.

[0140] The circular color blocks 120 in the four rectangular areas 10 are white (with a grayscale value of 255) circular patterns. Along the second preset "Z"-shaped path, the radii of the circular color blocks 120 in the four rectangular areas are 2.0 millimeters (mm), 1.5 millimeters (mm), 1.0 millimeters (mm), and 0.5 millimeters (mm), respectively. It should be noted that this embodiment only shows the case where the first preset path P1 and the second preset path P2 are the same. In some embodiments, the first preset path P1 and the second preset path P2 can also be different, which will not be repeated here.

[0141] At the same time, in order to distinguish the front and back directions of the first film 101 , a cut-off corner 130 is provided at one corner of the first film 101 .

[0142] The calibration block 2 includes a first battery profiling body 21, a second battery profiling body 22, a first tab profiling body 23, a second tab profiling body 24, a first film 101, and a second film 102. The first battery profiling body 21 is connected to the second battery profiling body 22 via the first tab profiling body 23 and the second tab profiling body 24. The first film 101 is attached to the surface of the first tab profiling body 23, and the second film 102 is attached to the surface of the second tab profiling body 24.

[0143] The first camera 31 and the second camera 32 are arranged along the first direction D1 and are respectively located directly above the first tab contour 23 and the second tab contour 24; the first camera 31 is used to capture a detection image of the first film 101, and the second camera 32 is used to capture a detection image of the second film 102;

[0144] The first bar light source 41 and the second bar light source 42 are respectively located on both sides of the first camera 31 and the second camera 32 along the second direction D2, the second direction D2 is perpendicular to the first direction D1, and the first bar light source 41 and the second bar light source 42 are both configured to simultaneously illuminate the first tab contour 23 and the second tab contour 24.

[0145] The host computer 5 is configured to determine the hardware inspection results of the first camera 31, the second camera 32, the first strip light source 41 and the second strip light source 42 based on the detection images captured by the first camera 31 and the second camera 32; the host computer 5 is also configured to determine the software inspection results of the visual inspection software in the host computer 5 based on the preset tab status image.

[0146] As shown in FIG4 , a method 400 for inspecting a tab ultrasonic welding detection system includes:

[0147] Step 410 : Acquire detection images of the first film 101 and the second film 102 .

[0148] Step 420: Determine the inspection parameters based on the inspection image;

[0149] Step 430: Determine hardware inspection results of the first camera 31, the second camera 32, the first bar light source 41, and the second bar light source 42 according to the inspection judgment parameters;

[0150] In step 430, the spot inspection judgment parameter is compared with the corresponding preset feature parameters, wherein the preset feature parameters include the grayscale value of the irregular color block 110 and the radius of the circular color block 120; in response to the difference between the spot inspection judgment parameter and the corresponding preset feature parameter exceeding the preset range, the hardware spot inspection result is determined to be failed.

[0151] The preset ranges mentioned above may include a grayscale threshold range and a length threshold range. The grayscale threshold range and the length threshold range are both determined based on the recognition capability of the tab ultrasonic welding detection system 1 and the defect type of the detection target, and are used to measure the reliability of the grayscale value recognition and size recognition of the tab ultrasonic welding detection system 1.

[0152] To test grayscale recognition capabilities, the difference in the image grayscale values ​​of any two irregularly shaped color blocks 110 in the preset feature parameters is compared with the difference in the corresponding two grayscale values ​​in the spot inspection judgment parameters. The difference, ΔT2, is calculated to see whether it exceeds the preset grayscale threshold range, that is, whether it satisfies -5 ≤ ΔT2 ≤ 5. If so, the tab ultrasonic welding inspection system is deemed to have met the grayscale recognition requirements.

[0153] For the detection of size recognition capability, the size threshold range can be determined based on the size tolerance of the circular color block 120 in the first film 101 or the second film 102. In some embodiments, the radius tolerance of the circular color block 120 in the first film 101 is The size threshold range can be less than or equal to That is, the image radius of any circular color block 120 in the image feature parameter can be compared with the corresponding radius value in the preset feature parameter, and the difference △T3 between the two can be calculated to see whether it exceeds the preset size threshold range, that is, whether it satisfies the requirement. If so, it is determined that the size recognition capability of the tab ultrasonic welding detection system 1 meets the requirements.

[0154] When the recognition capability of the determined size meets the requirements and the recognition capability of the grayscale value meets the requirements, the hardware inspection result can be considered to have passed.

[0155] Step 440: Acquire a preset tab state image, where the preset tab state image includes at least one image of a tab with a preset defect and / or an image of a tab without a defect.

[0156] Step 450: Determine a defect detection result according to a preset tab state image.

[0157] Step 460: Determine the software inspection result of the visual inspection software in the host computer 5 according to the defect detection result.

[0158] In step 460, if the defect detection result of the preset tab state image is consistent with the preset result, it indicates that the visual inspection software of the tab ultrasonic welding detection system 1 is operating normally, and the software inspection result of the tab ultrasonic welding detection system 1 is passed. If it is inconsistent, it indicates that the visual inspection software of the tab ultrasonic welding detection system 1 may have an algorithm mutation or algorithm failure, and the software inspection result of the tab ultrasonic welding detection system 1 is failed. The tab ultrasonic welding detection system 1 needs to be debugged and re-inspected after debugging is completed until the software inspection result passes.

[0159] Thus, steps 410 to 430 are to perform a spot check on the hardware reliability of the tab ultrasonic welding detection system 1, and steps 440 to 460 are to perform a spot check on the software reliability of the tab ultrasonic welding detection system 1. After completing the spot check of the tab ultrasonic welding detection system 1 through the above steps, it can be confirmed that the reliability of the tab ultrasonic welding detection system 1 meets production requirements.

[0160] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application, and they should all be included in the scope of the claims and specification of the present application. In particular, as long as there is no structural conflict, the various technical features mentioned in the various embodiments can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions that fall within the scope of the claims.

Claims

1. A tab ultrasonic welding detection system, comprising: The calibration block includes a first battery shaped body, a second battery shaped body, a first tab shaped body, a second tab shaped body, a first film sheet, and a second film sheet, wherein the first battery shaped body is connected to the second battery shaped body via the first tab shaped body and the second tab shaped body, the first film sheet is attached to the surface of the first tab shaped body, and the second film sheet is attached to the surface of the second tab shaped body; A first camera and a second camera are arranged along a first direction and are respectively located directly above the first tab contour body and the second tab contour body; the first camera is used to capture a detection image of the first film sheet, and the second camera is used to capture a detection image of the second film sheet; a first bar light source and a second bar light source, wherein the first bar light source and the second bar light source are respectively located on either side of the first camera and the second camera along a second direction, the second direction being perpendicular to the first direction, and the first bar light source and the second bar light source are both configured to simultaneously illuminate the first tab shaped body and the second tab shaped body; as well as The host computer is configured to determine the hardware inspection results of the first camera, the second camera, the first strip light source and the second strip light source based on the detection images captured by the first camera and the second camera; the host computer is also configured to determine the software inspection results of the visual inspection software in the host computer based on the preset tab status image.

2. The tab ultrasonic welding detection system according to claim 1, wherein: The surfaces of the first tab shaped body and the second tab shaped body facing the first camera and the second camera are respectively provided with grooves, and the grooves are used to accommodate the first film sheet and the second film sheet, so that the upper surfaces of the first film sheet and the second film sheet are flush with the surfaces of the first tab shaped body and the second tab shaped body respectively.

3. The tab ultrasonic welding detection system according to claim 1 or 2, wherein: The first film and the second film each include a plurality of rectangular areas, each of the rectangular areas includes a circular color block and a irregular color block surrounding the circular color block, and in each of the rectangular areas, the circular color block and the irregular color block surrounding the circular color block have different grayscale values.

4. The tab ultrasonic welding detection system according to claim 3, wherein: The radii of the plurality of circular color blocks are different from each other, and the grayscale values ​​of the plurality of irregular color blocks are different from each other.

5. The tab ultrasonic welding detection system according to claim 4, wherein: Along the first preset path that passes through each of the rectangular areas in sequence, the grayscale value of the irregular color block gradually increases or decreases.

6. The tab ultrasonic welding detection system according to claim 5, wherein: The smallest radius of the multiple circular color blocks is greater than or equal to the minimum detection size of the first camera and the second camera, and along the second preset path that passes through each of the rectangular areas in sequence, the radius of the circular color blocks increases or decreases by an integer multiple of the minimum detection size.

7. The tab ultrasonic welding detection system according to claim 5 or 6, wherein: The grayscale value of the irregular color block gradually increases or decreases in an arithmetically progressive manner along the first preset path.

8. The tab ultrasonic welding detection system according to any one of claims 3 to 7, wherein: The grayscale value of the plurality of circular color blocks is 255.

9. The tab ultrasonic welding detection system according to any one of claims 3 to 8, wherein the first film sheet and / or the second film sheet comprises a cut-off angle, and the cut-off angle is used to distinguish the front and back directions of the first film sheet and / or the second film sheet.

10. The tab ultrasonic welding detection system according to any one of claims 3 to 9, wherein: The host computer is configured to determine the spot inspection judgment parameters according to the detection image, and Determine the hardware spot inspection result according to the spot inspection judgment parameter; The spot inspection judgment parameters include a detection value of the grayscale value of the irregular color block and a detection value of the radius of the circular color block in the detection image.

11. The tab ultrasonic welding detection system according to any one of claims 1 to 10, wherein: The host computer is further configured to determine a tab defect detection result according to the preset tab state image, and The software spot inspection result is determined according to the tab defect detection result and a preset defect result corresponding to the preset tab state image.

12. The tab ultrasonic welding detection system according to any one of claims 1 to 11, wherein: The tab ultrasonic welding detection system also includes a lower computer and a clamp. The upper computer is also configured to send the hardware inspection result to the manufacturing execution system. In response to the hardware inspection result being passed, the upper computer sends the hardware inspection result to the lower computer, and the lower computer controls the clamp to remove the calibration block.

13. A spot inspection method for a tab ultrasonic welding detection system, the spot inspection method being performed in the tab ultrasonic welding detection system according to any one of claims 1 to 12, the spot inspection method comprising: Acquire detection images of the first film sheet and the second film sheet; Determining spot inspection judgment parameters according to the detection image; Determining hardware spot inspection results of the first camera, the second camera, the first bar light source, and the second bar light source according to the spot inspection judgment parameters; Acquire a preset tab state image, wherein the preset tab state image includes at least one image of a tab with a preset defect and / or an image of a tab without a defect; determining a defect detection result according to the preset tab state image, and The software inspection result of the visual inspection software in the host computer is determined according to the defect detection result.

14. The inspection method of the tab ultrasonic welding detection system according to claim 13, wherein: The first film and the second film each include a plurality of rectangular areas, each of the rectangular areas includes a circular color block and a special-shaped color block surrounding the circular color block, the radii of the plurality of circular color blocks are different from each other, and the grayscale values ​​of the plurality of special-shaped color blocks are different from each other; And wherein, the spot inspection judgment parameter includes the detection value of the gray value of the irregular color block and the detection value of the radius of the circular color block in the detection image.

15. The inspection method of the tab ultrasonic welding detection system according to claim 14, wherein: The determining of hardware spot inspection results of the first camera, the second camera, the first bar light source, and the second bar light source according to the spot inspection judgment parameters includes: Comparing the spot inspection judgment parameter with corresponding preset characteristic parameters, wherein the preset characteristic parameters include the grayscale value of the irregular color block and the radius of the circular color block; In response to a difference between the spot inspection determination parameter and the corresponding preset characteristic parameter exceeding a preset range, the hardware spot inspection result is determined to be failed.

16. The inspection method of the tab ultrasonic welding detection system according to claim 15, wherein: The determining of hardware spot inspection results of the first camera, the second camera, the first bar light source, and the second bar light source according to the spot inspection judgment parameter further includes: In response to the deviation of the difference between the grayscale values ​​of any two of the irregular color blocks and the grayscale value difference in the corresponding preset characteristic parameters exceeding the grayscale threshold range, the hardware inspection result is determined to be failed.

17. The inspection method of the tab ultrasonic welding detection system according to claim 15 or 16, wherein: The determining of hardware spot inspection results of the first camera, the second camera, the first bar light source, and the second bar light source according to the spot inspection judgment parameter further includes: In response to a deviation between a detected value of the radius of any of the circular color blocks and a radius in the corresponding preset characteristic parameter exceeding a size threshold range, the hardware spot inspection result is determined to be failed.

18. The inspection method of a tab ultrasonic welding detection system according to any one of claims 14 to 17, wherein: Determining the software inspection result of the visual inspection software in the host computer according to the defect detection result includes: Compare the defect detection result with the preset defect result corresponding to the preset tab state image, In response to the defect detection result being inconsistent with the preset defect result, the software spot inspection result of the visual inspection software in the host computer is determined to be failed.

19. The inspection method of a tab ultrasonic welding detection system according to any one of claims 14 to 18, wherein: Also includes: In response to a failure result of the hardware spot inspection, adjusting the first camera, the second camera, the first bar light source, and the second bar light source; and / or In response to the software spot inspection result being a failure, software debugging is performed on the host computer of the tab ultrasonic welding detection system.

20. The inspection method of a tab ultrasonic welding detection system according to any one of claims 14 to 19, wherein: The tab ultrasonic welding detection system further includes a lower computer and a clamping jaw, and the inspection method further includes: Sending the hardware inspection result to a manufacturing execution system; In response to the hardware spot inspection result being passed, the hardware spot inspection result is sent to the lower computer, and the lower computer controls the clamp to remove the calibration block.

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