Battery X-Ray Corner Inspection for Distortion-Free Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery testing methods suffer from misjudgment, omissions, and incomplete testing due to distorted images of battery corners, particularly in stacked batteries, which are not accurately captured when rays are not perpendicular to the surface, leading to inaccurate defect detection.
Innovation Solution
A battery testing apparatus with multiple ray sources and detectors positioned to ensure rays are nearly perpendicular to battery corners, using small focal sizes for enhanced imaging to reduce distortions and improve accuracy, allowing comprehensive defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single ray source and detector are used for battery testing, then the device complexity is low, but the measurement precision of corner defects is insufficient due to image distortion
Solution Approach 1:
The testing apparatus is divided into multiple independent ray source-detector pairs, each dedicated to testing a specific corner of the battery. This segmentation allows each pair to capture images with minimal distortion while maintaining overall system manageability through modular architecture.
Solution Approach 2:
The patent transitions from a single testing perspective to multiple spatial perspectives by positioning ray sources and detectors at different locations around the battery. This multi-dimensional approach enables comprehensive corner coverage with perpendicular ray incidence, eliminating the image distortion problem of single-point testing.
2Area of stationary object
If ray sources are positioned far from battery corners to cover the entire corner area, then the area coverage is improved, but the geometric unsharpness increases reducing image resolution
Solution Approach 1:
Each ray source-detector pair is positioned to optimize local imaging quality at its specific corner target. The ray source focal spot size is controlled to be small (≤10 μm) to minimize geometric unsharpness, while the perpendicular positioning ensures optimal penetration and image quality for that specific corner region.
Solution Approach 2:
The patent controls the ray source focal spot size parameter to be less than or equal to 10 microns, significantly reducing geometric unsharpness. This parameter optimization allows the system to achieve high-resolution corner images without requiring excessive distance between the ray source and the battery corner.
3Reliability
If multiple ray sources and detectors are added to test all battery corners, then the measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The testing system is segmented into multiple independent ray source-detector pairs, each responsible for a specific corner. This modular segmentation ensures comprehensive defect testing coverage while maintaining system manageability through standardized repeating units.
Solution Approach 2:
Each ray source-detector pair is designed as a universal module that can test any corner of the battery when positioned appropriately. The bearing platform enables these universal modules to adapt to different testing positions, reducing the need for completely separate specialized equipment for each corner.
4Adaptability or versatility
If the bearing platform moves to position batteries for testing, then the adaptability is improved, but the testing time increases due to movement requirements
Solution Approach 1:
The bearing platform is designed with pre-defined movement trajectories that automatically position batteries in the correct locations for each corner test. This preliminary positioning action eliminates the need for manual adjustment and ensures rapid, repeatable placement, reducing overall testing time while maintaining positioning flexibility.
Solution Approach 2:
The bearing platform provides dynamic positioning capability, automatically moving batteries between different testing positions according to the test sequence. This dynamic automation replaces manual positioning, improving both the adaptability to test different corners and the speed of the testing process through programmed motion.
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 apparatus provides more accurate and comprehensive defect testing by minimizing image distortions at battery corners, reducing misjudgment and omissions, and enhancing the reliability of battery quality assessment.
Implementation Method 1
a first ray source; a second ray source; a first detector, opposite to an exit port of the first ray source; a second detector, opposite to an exit port of the second ray source
Data Source
AI summary
A testing apparatus and method for testing a battery, a device, and a medium are disclosed. The testing apparatus includes a first ray source, a first detector, a second ray source, a second detector, a bearing platform, and a testing unit. The bearing platform is configured to place a battery to be tested, and the bearing platform is movable. A movement trajectory of the bearing platform passes between the first ray source and the first detector, and the movement trajectory of the bearing platform passes between the second ray source and the second detector. The testing unit is respectively connected to the first detector and the second detector. The testing unit is configured to perform defect testing on the battery to be tested based on a ray received by the first detector and a ray received by the second detector.