3D Resin Inspection for Faster Battery Module Production
Solution Overview
Problem
The manufacturing process of secondary batteries is hindered by inefficiencies in inspecting and applying resin compositions, leading to increased tact time and reduced productivity.
Innovation Solution
An inspection device that includes a scanner to determine the 3D profile and analyzer to measure the area and mass of resin compositions on a frame, integrated with a system for automated application and inspection, reducing the need for manual intervention and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional inspection methods are used to measure resin composition, then measurement accuracy is maintained, but tact time increases and productivity decreases
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with an optical scanning system using laser sources and detectors to measure resin composition height and calculate mass, enabling non-contact rapid inspection that reduces tact time while maintaining measurement accuracy
Solution Approach 2:
The system changes the measurement parameter from direct mass measurement to height measurement via 3D scanning, then calculates mass based on the relationship between height, area, and resin density, enabling faster inspection without sacrificing measurement capability
2Reliability
If comprehensive inspection of resin composition mass and area is performed, then quality control is improved, but inspection complexity and time increase
Solution Approach 1:
The scanning system performs multiple functions including 3D profile measurement, area calculation, mass determination, and defect detection using a single integrated device with laser source, scanner, and detector, reducing overall system complexity while improving quality control reliability
Solution Approach 2:
The system creates a 3D digital copy of the resin composition surface profile through laser scanning and height measurement, then performs all analysis calculations on this digital model, simplifying the inspection process while enabling comprehensive quality assessment
3Measurement precision
If manual inspection methods are used for resin composition, then equipment cost is reduced, but measurement precision and consistency deteriorate
Solution Approach 1:
The patent replaces manual inspection with an automated optical measurement system using laser sources and detectors that non-contactly measure resin height and calculate mass, providing consistent precise measurements without the variability inherent in manual methods
Solution Approach 2:
The inspection system performs self-measurement and self-analysis by automatically scanning the resin composition, calculating area and mass from 3D profile data, and providing quality assessment without requiring manual intervention, ensuring measurement consistency and precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces tact time and increases productivity by accurately measuring and ensuring the quality of resin application on battery modules, thereby improving manufacturing efficiency.
Implementation Method 1
a laser source configured to generate an optical signal
Implementation Method 2
a detector configured to detect the optical signal reflected from a surface of the resin composition
Implementation Method 3
The scanner may be a time-of-flight (TOF) scanner
Data Source
AI summary
Provided is an inspection device according to example embodiments. The inspection device includes a scanner configured to scan a resin composition on a frame to determine a three-dimensional (3D) profile of the frame and the resin composition on the frame, and an analyzer configured to determine an area and mass of the resin composition based on the 3D profile.