Battery Module Lead Inspection Using Two-Stage Vision Checks
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Solution Overview
Problem
Existing battery module inspection methods rely on manual visual inspections, leading to human errors and increased labor costs, which can result in erroneous inspections during the assembly of battery modules.
Innovation Solution
A battery module inspection method utilizing vision cameras to automatically inspect the number, position, and bending states of electrode leads in battery cells, preventing erroneous assembly by performing vision inspection before and after the cell stack is assembled with busbar frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used to detect foreign objects and defects in battery modules, then flexibility and adaptability are maintained, but inspection efficiency and productivity are significantly reduced
Solution Approach 1:
The inspection system is divided into multiple independent modules: laser projection module, camera module, control unit, and processing unit. Each module performs a specific function (projecting lines, capturing images, controlling parameters, analyzing data), allowing the system to achieve high automation and productivity while maintaining modularity that reduces overall system complexity.
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated optical measurement system using laser lines and image capture. This substitution eliminates the need for physical contact and manual operation, dramatically improving inspection efficiency and productivity while the digital processing approach keeps the system manageable in complexity.
2Measurement precision
If traditional inspection methods are used, then device complexity remains low, but measurement precision and detection capability are insufficient
Solution Approach 1:
The system pre-processes the captured images by subtracting a reference image (taken without foreign objects) from the current inspection image. This preliminary action highlights only the differences, making foreign objects and defects immediately visible and significantly improving detection precision while keeping the analysis relatively simple.
Solution Approach 2:
The patent uses visual color/intensity changes in the processed images to indicate the presence of foreign objects. Areas with foreign objects appear as distinct patterns in the subtracted image, providing clear visual cues that enhance measurement precision without requiring complex analytical algorithms.
3Productivity
If automated inspection systems are implemented, then productivity increases, but the complexity of the inspection device increases
Solution Approach 1:
The laser projection system can project multiple line patterns (single line, double line, grid patterns) to inspect different features of the battery module. The same hardware setup serves multiple inspection purposes, increasing productivity without proportionally increasing device complexity.
Solution Approach 2:
The system creates a digital copy of the battery module surface by projecting laser lines and capturing the reflected light with a camera. This optical copying approach enables automated, high-speed inspection while avoiding the complexity of physical measurement devices or contact-based inspection methods.
4Measurement precision
If detailed inspection of battery modules is performed, then measurement precision improves, but inspection time increases reducing productivity
Solution Approach 1:
The inspection process uses periodic laser line projection followed by rapid image capture and immediate processing. This periodic action allows the system to inspect multiple areas sequentially with high speed, maintaining detailed precision while minimizing total inspection time through efficient cycling of the measurement and processing steps.
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 method reduces the occurrence of human errors by automating the inspection process, ensuring accurate assembly of battery modules and reducing labor costs.
Implementation Method 1
provides a laser to project light lines on the battery module
Implementation Method 2
provides an image acquisition device to capture images of the battery module under the action of the light lines
Data Source
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AI summary
The present invention relates to a battery module inspection method, and the battery module inspection method according to the present invention includes: a first vision inspection process of inspecting a cell stack in which multiple battery cells are stacked, wherein the number and positions of electrode leads included in the multiple battery cells, respectively, are inspected through a vision camera; and a second vision inspection process of inspecting the number and bending states of the electrode leads provided in the multiple battery cells, respectively, through the vision camera after the first vision inspection process.