Dual Lighting Inspection for Battery Fillet Connection Integrity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical inspection methods for rechargeable battery electrode plate-connected structures face issues with accurately assessing the connection strength of fillets between electrode plates and current collector plates, as bent portions can shield inspection light, leading to erroneous defects and potential halation with increased illuminance.
Innovation Solution
An inspection apparatus and method utilizing dual lighting setups, where a first lighting device captures a front lighting image and a second lighting device captures a back lighting image, allowing for accurate analysis of fillet connection states without halation, by positioning the imaging device to receive reflected light and transmitted light respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If inspection light illuminance is increased to penetrate bent portions, then detection capability improves, but halation occurs causing imaging errors
Solution Approach 1:
The inspection system is segmented into two independent lighting devices: a first lighting device for front lighting and a second lighting device for back lighting. Each lighting device operates independently to capture different types of information, allowing the system to overcome the limitations of single-lighting approaches where increased illuminance causes halation.
Solution Approach 2:
The inspection approach transitions from a single-dimensional lighting method to a two-dimensional lighting approach by adding back lighting in addition to front lighting. This dimensional expansion allows simultaneous capture of surface information (front lighting) and internal connection information (back lighting) without the harmful effects of excessive illuminance in any single direction.
2Adaptability or versatility
If bent portions are present in electrode plates, then structural flexibility improves, but light shielding occurs causing erroneous defect detection
Solution Approach 1:
The second lighting device (back lighting) acts as an intermediary that provides light transmission through the electrode plate from the rear side. This allows inspection light to penetrate bent portions that would otherwise shield the connection, enabling accurate detection of fillet formation without compromising the structural flexibility provided by bent portions.
3Device complexity
If single lighting method is used to simplify device structure, then device complexity reduces, but inspection accuracy deteriorates due to halation and light shielding
Solution Approach 1:
The lighting system is divided into two separate lighting devices with distinct functions: front lighting for surface illumination and back lighting for transmission through the electrode plate. This segmentation allows each device to operate at optimal illuminance levels without causing halation, while maintaining relatively simple individual device structures.
Solution Approach 2:
The dual lighting system provides multi-functionality by simultaneously enabling surface inspection (front lighting) and internal connection inspection (back lighting). This universal approach covers various inspection needs within a single system framework, achieving comprehensive inspection accuracy without requiring multiple separate inspection systems.
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
This approach effectively reduces erroneous defect determinations and enhances the accuracy of fillet inspection, ensuring reliable connection strength evaluation by combining front and back lighting images to assess fillet formation and connection integrity.
Implementation Method 1
a first lighting device (26) arranged on the one side for emitting inspection light to the rechargeable battery electrode plate-connected structure
Implementation Method 2
a second lighting device (27) arranged facing toward the imaging device (25) with the rechargeable battery electrode plate-connected structure in between for emitting inspection light to the rechargeable battery electrode plate-connected structure
Data Source
AI summary
An inspection apparatus for inspecting a rechargeable battery electrode plate-connected structure to check whether electrode plates are properly connected to a current collector plate by filters. The apparatus includes an imaging device arranged on one side of the rechargeable battery electrode plate-connected structure, a first lighting device which illuminates the rechargeable battery electrode plate-connected structure at the same side of the rechargeable battery electrode plate-connected structure as the first lighting device, a second lighting device which illuminates the rechargeable battery electrode plate-connected structure from the opposite side of the rechargeable battery electrode plate-connected structure, and an inspection circuit connected to the imaging device which inspects the connection state of the fillets by analyzing a front lighting image captured by the imaging device when only the first lighting device emits light and a back lighting image captured when only the second lighting device emits light.