Battery Cell Height Sensing for Tab Lift Detection
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Solution Overview
Problem
Existing methods for detecting abnormal states of battery cells, such as lifted tabs or biased disposition, are inaccurate and unclear due to reliance on visual inspection during transportation, and are difficult to apply when space is limited between the battery terminal and mounting unit.
Innovation Solution
A method and device using a height measurement unit on a mounting unit to acquire height information regarding the battery cell, determining its state based on first and second height information, allowing for accurate detection of tab lift and normal disposition using laser, ultrasonic, or infrared light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a worker visually inspects battery cells during transportation, then inspection can be performed, but the accuracy of the inspection result is low and the result is unclear
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system. A camera captures images of the battery cell tabs, and image processing algorithms automatically measure tab heights and positions, eliminating human subjectivity and improving measurement accuracy and consistency.
Solution Approach 2:
The patent creates a digital copy (image) of the battery cell tab structure and analyzes this copy computationally. By capturing the physical tab structure as an image and performing measurements on the digital representation, the system achieves precise, repeatable measurements without physical contact with the moving cells.
2Reliability
If lighting and camera are disposed between the battery terminal and mounting unit as in prior art, then terminal defect detection is possible, but sufficient space cannot be secured when the terminal is disposed on a horizontal plane parallel to the upper surface of the mounting unit
Solution Approach 1:
The patent changes the spatial arrangement from a horizontal configuration (lighting and camera between terminal and mounting unit in the same plane) to a vertical configuration (lighting above the terminal, camera below). This dimensional change allows the system to function in constrained horizontal spaces while maintaining defect detection capability.
Solution Approach 2:
The patent inverts the traditional lighting-camera arrangement. Instead of placing both components on one side of the terminal, the lighting is positioned above the terminal and the camera below, creating a through-illumination setup that enables measurement in limited space configurations.
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 precise detection of battery cell states, improving accuracy and clarity in identifying abnormal conditions, even in constrained spaces, by analyzing height differences with a controller-driven analysis.
Implementation Method 1
allowing for accurate detection of tab lift and normal disposition using laser, ultrasonic, or infrared light
Implementation Method 2
allowing for accurate detection of tab lift and normal disposition using laser, ultrasonic, or infrared light
Implementation Method 3
allowing for accurate detection of tab lift and normal disposition using laser, ultrasonic, or infrared light
Data Source
AI summary
A device and method of sensing a state of a battery cell disposed on a mounting unit are disclosed. The method includes a height information acquisition step of acquiring, by a height measurement unit disposed on the mounting unit on which the battery cell is disposed, first height information on a first height that is a height of the height measurement unit with respect to a point of the mounting unit and second height information on a second height that is the height of the height measurement unit with respect to a point of the battery cell, and a battery cell state analysis step of determining, by a controller, a state of the battery cell based on the first height information and the second height information.