Battery Cover Welding Point Check Using Calibration Block Imaging
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Solution Overview
Problem
Existing battery housing cover welding systems face challenges in ensuring stable and reliable operation, leading to potential faults and defects due to issues like damaged light sources, contaminated lenses, and loose cable connections, which are difficult to detect and correct efficiently.
Innovation Solution
A battery housing cover welding system equipped with a calibration block featuring specific surface and side surface features, combined with multiple cameras and a host computer, allows for automated and precise image acquisition and analysis to determine hardware and software point check results, reducing manual intervention and errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual checking methods are used for the battery housing cover welding system, then operational flexibility is maintained, but checking efficiency and accuracy deteriorate due to human error and time consumption
Solution Approach 1:
The patent replaces manual mechanical checking operations with an automated optical inspection system comprising multiple cameras, light sources, and image processing units. The system automatically captures images of calibration blocks with known features, processes them through computer vision algorithms, and compares measured features against reference data to detect faults, eliminating human intervention entirely.
Solution Approach 2:
The system performs self-verification by automatically comparing captured images of calibration features against pre-stored reference data. The image processing unit autonomously identifies features, measures their parameters, and determines whether deviations indicate system faults, enabling the system to self-diagnose without external intervention.
2Reliability
If multiple cameras and calibration blocks are introduced for automated inspection, then measurement precision and reliability improve, but device complexity increases
Solution Approach 1:
The inspection system is divided into modular functional units: multiple cameras positioned at different angles, separate light sources for illumination, an image processing unit for analysis, and a control unit for coordination. Each component performs a specific function, allowing independent optimization and maintenance while contributing to overall system reliability.
Solution Approach 2:
The calibration block serves as an intermediary reference object with precisely manufactured features of known dimensions. It mediates between the physical welding system being inspected and the digital image processing system, providing a stable reference for accuracy verification and fault detection without requiring direct contact or complex interaction between the inspection components.
3Loss of time
If automated image acquisition and analysis is implemented, then checking speed and accuracy improve, but the requirement for precise calibration and setup increases
Solution Approach 1:
The calibration block is pre-manufactured with features of precisely known dimensions and positions before the inspection system is deployed. Reference data for these features is pre-calculated and stored in the system's database. This preliminary preparation eliminates the need for time-consuming on-site calibration procedures, allowing the system to immediately begin accurate fault detection upon installation.
Data Source
AI summary
A battery housing cover welding system and a point check method are described. The system includes a calibration block including a battery profiling body which includes: a top surface, a first side surface joined to the top surface through a first edge, a second side surface joined to the top surface through a second edge, a third side surface joined to the top surface through a third edge, and a fourth side surface joined to the top surface through a fourth edge; a first surface feature, a second surface feature, a third surface feature, and a fourth surface feature that are disposed near the first edge, the second edge, the third edge, and the fourth edge, respectively, and all located on the top surface.