Battery Pack Bonding Diagnosis with Thermal-Magnetic Imaging

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing battery pack manufacturing processes fail to accurately inspect the bonding state of hundreds of battery cells and wires, leading to potential defects that can cause variations in internal resistance, reduced output, and even short-circuits, which are difficult to diagnose due to the large number of connections.

Innovation Solution

A method combining thermal and magnetic field image analysis during battery cell charging and discharging to diagnose the bonding state of battery cells and wires, involving thermal image photographing, reading, and magnetic field image photographing and reading, followed by a comprehensive defect determination process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If thermal image reading alone is used to diagnose bonding state, then the diagnosis process is simple, but the diagnosis precision is insufficient

Engineering Contradiction:
Improvediagnosis process complexityVSAvoidbonding state diagnosis precision
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent combines thermal image reading and magnetic field image reading into a unified diagnosis system. The bonding state is determined by integrating both thermal data (indicating abnormal connections) and magnetic field data (indicating normal connections), thereby improving diagnosis precision while maintaining process simplicity through a coordinated multi-modal approach.

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If magnetic field image reading alone is used to diagnose bonding state, then the diagnosis process is simple, but the diagnosis precision is insufficient

Engineering Contradiction:
Improvediagnosis process complexityVSAvoidbonding state diagnosis precision
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent integrates magnetic field image reading with thermal image reading to create a comprehensive diagnosis system. Magnetic field data provides information about normal connections, which complements the thermal data, thereby improving overall diagnosis precision while keeping the process manageable through systematic integration.

Inventive Principle:
Principle #5Merging (Combining)

3Measurement precision

If both thermal and magnetic field image reading are combined to diagnose bonding state, then the diagnosis precision is improved, but the device complexity increases

Engineering Contradiction:
Improvebonding state diagnosis precisionVSAvoiddiagnosis system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the diagnosis process into distinct sequential stages: thermal image reading, magnetic field image reading, and integrated analysis. Each stage handles specific data types and processing tasks independently, then combines results in a structured manner. This segmentation reduces system complexity by organizing the multi-modal integration into manageable, modular components.

Inventive Principle:
Principle #1Segmentation

4Measurement precision

If several hundreds of battery cells and wires are inspected individually, then the bonding state of each connection can be exactly inspected, but the inspection time and complexity increase significantly

Engineering Contradiction:
Improvebonding state inspection accuracyVSAvoidinspection time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent merges the inspection of hundreds of battery cells and wires into a single batch process using thermal and magnetic field imaging. Instead of individually inspecting each connection, the system captures comprehensive thermal and magnetic field data across the entire battery pack simultaneously, then processes the data to identify bonding states of all connections in one unified analysis, dramatically reducing inspection time while maintaining precision.

Inventive Principle:
Principle #5Merging (Combining)

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

Enables precise diagnosis of bonding states by cross-validating thermal and magnetic field image data, ensuring defective connections are identified, preventing output degradation and safety issues.

Implementation Method 1

a battery pack thermal image photographing process of photographing a thermal image of the battery pack

Methodology Applied
Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

a battery pack magnetic field image photographing process of photographing a magnetic field image of the battery pack

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250216468A1Method for diagnosing battery pack
Publication Date: 2025.07.03 LG ENERGY SOLUTION LTD
  • US20250216468A1 patent drawing
  • US20250216468A1 patent drawing
  • US20250216468A1 patent drawing

AI summary

Discussed is a battery pack diagnosis method including a battery pack manufacturing process, a battery cell charging and discharging process, a battery pack thermal image photographing process, a thermal image reading process, a battery pack magnetic field image photographing process, a magnetic field image reading process, and a wire bonding state defect determining process of finally determining a bonding state of a battery cell and a wire by combining thermal image reading result information obtained in the thermal image reading process and magnetic field image reading result information obtained in the magnetic field image reading process in order to exactly diagnose the bonding state of the battery cell and the wire connecting the battery cell in the battery pack.