Battery Cap Assembly Crack Inspection Using Optical Reference Marks
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Solution Overview
Problem
Existing technologies face challenges in ensuring proper assembly of cap assemblies in secondary batteries, leading to potential cracks and reduced reliability and safety due to loose components or vent cracks during the manufacturing process.
Innovation Solution
A cap assembly design with a vent, cap down, and insulator, featuring a mark and/or sub-mark for non-destructive inspection of cracks, and a secondary battery inspection device using a vision camera and processor to inspect the cap assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly inspection methods are used, then manufacturing cost is reduced, but crack detection capability is insufficient and reliability is compromised
Solution Approach 1:
The patent uses optical imaging to create a visual copy of the cap assembly's surface and internal structure. The mark positioned on the cap down serves as a reference feature in this optical copy, enabling the inspection system to detect cracks and assembly defects by comparing the imaged structure against the known mark position and expected geometry, without requiring physical contact or complex tactile sensors.
Solution Approach 2:
The patent introduces an optical field as an intermediary between the inspection system and the cap assembly. The vision camera captures light reflected from or transmitted through the cap assembly, and the mark serves as an intermediary reference feature that facilitates the detection of cracks by providing a known geometric reference point for comparison and analysis.
2Measurement precision
If destructive inspection methods are used, then crack detection accuracy is improved, but product damage occurs and productivity is reduced
Solution Approach 1:
The patent replaces mechanical or destructive inspection methods with an optical-based vision inspection system. Instead of using physical contact, probing, or destructive testing to detect cracks, the system uses light transmission and reflection principles to capture images of the cap assembly, allowing non-contact, non-destructive detection of cracks and assembly defects with high precision.
Solution Approach 2:
The cap assembly's own optical properties (light transmission, reflection, and absorption) are utilized for self-inspection. The mark on the cap down serves as an intrinsic reference feature that enables the assembly to provide its own inspection data when illuminated, allowing the system to detect cracks and defects through the assembly's natural interaction with light without requiring external physical intervention.
3Reliability
If comprehensive inspection coverage is achieved, then reliability is improved, but inspection time increases and productivity decreases
Solution Approach 1:
The mark is pre-positioned on the cap down during manufacturing, serving as a prepared reference feature that enables rapid inspection. This preliminary action of placing the mark during assembly ensures that during inspection, the system can immediately use this known reference point to quickly detect cracks and assembly defects without requiring complex setup or calibration time, thus maintaining high inspection speed while achieving comprehensive coverage.
Solution Approach 2:
The vision inspection system is designed to perform multiple inspection functions simultaneously using a single imaging operation. The system can detect cracks, verify assembly completeness, check mark positioning, and identify other defects all in one inspection cycle, achieving comprehensive inspection coverage without proportionally increasing inspection time, thereby maintaining high productivity while improving reliability.
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
Enables reliable and safe assembly inspection by detecting cracks without damaging the cap assembly, ensuring the integrity and safety of secondary batteries.
Implementation Method 1
a vision camera configured to acquire an image of a cap assembly
Implementation Method 2
a vision camera configured to acquire an image of a cap assembly
Data Source
AI summary
A cap assembly, a secondary battery including the cap assembly, and an inspection device for inspecting the secondary battery are disclosed. A cap assembly includes a cap down, a vent located on a surface of the cap down, and a mark located on another surface of the cap down.