Battery Electrode Foreign-Matter Detection With Directional Lighting
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Solution Overview
Problem
Conventional quality inspection methods for rechargeable batteries are inadequate in detecting small foreign substances, particularly metal foreign materials and thin-film foreign materials, due to low visibility and reliance on color difference-based dimensional inspection.
Innovation Solution
A device comprising a lighting unit that irradiates light brighter in one direction or uniformly, a photographing unit, a controller, and a processor, which synthesizes images using an RGB color method and machine-learned model to accurately detect foreign substances on electrode plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional color difference-based dimensional inspection is used, then the inspection process is simple, but small foreign substances (metal and thin-film) cannot be detected due to low visibility
Solution Approach 1:
The inspection system is divided into multiple specialized components: lighting unit with multiple light sources, photographing unit with multiple cameras, and processing unit. Each component performs a specific function, and their coordinated operation enables detection of foreign substances that cannot be detected by conventional single-method inspection systems
Solution Approach 2:
Multiple intermediate imaging processes are introduced between the object and final detection. The system captures images under different lighting conditions (transmitted light, reflected light, oblique light) and processes them through multiple stages including image synthesis and difference image generation, enabling detection of subtle foreign substance characteristics
2Measurement precision
If multiple lighting directions and image synthesis methods are used, then foreign substance visibility is enhanced, but processing time and system complexity increase
Solution Approach 1:
The system performs preliminary image acquisition under multiple lighting conditions simultaneously or in predetermined sequences before final processing. Images from different lighting angles and types are captured in advance, allowing the processing unit to work with pre-prepared data sets rather than acquiring images on-demand during analysis
Solution Approach 2:
The system changes lighting parameters (intensity, angle, type) to optimize foreign substance visibility. By varying these parameters across multiple captured images and synthesizing them, the system enhances contrast and visibility of foreign substances without requiring excessive processing of a single complex image
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
Enhances visibility of foreign substances, allowing precise detection and reducing defect rates in battery manufacturing while increasing productivity by accurately distinguishing between similar and dissimilar materials.
Implementation Method 1
a lighting unit capable of irradiating light toward an object that is brighter in one direction than in other directions or uniformly irradiating light toward the object
Implementation Method 2
a diffusion member made of a transparent material, installed in the penetrated portion of the body member, and the diffusion member capable of diffusing light irradiated by the light-emitting device
Implementation Method 3
a photographing unit spaced from the lighting unit and capable of photographing the object
Data Source
AI summary
A device for detecting foreign substances comprising: a lighting unit for irradiating light toward an object that is brighter in one direction than other directions or uniformly irradiating light toward the object; a photographing unit spaced from the lighting unit and capable of photographing the object; a controller capable of: allowing the photographing unit to the photograph the object each time the lighting unit irradiates light toward the object that is brighter in one direction than other directions, and controlling the lighting unit and the photographing unit to allow the photographing unit to photograph the object if the lighting unit uniformly irradiates light toward the object; and a processor capable of synthesizing images photographed by the photographing unit and determining whether the object has foreign substances from the synthesized image.