Battery Sheet Roll Quality Monitoring with Integrated Defect Mapping
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Solution Overview
Problem
Current manufacturing systems for lithium-ion batteries face challenges in accurately detecting and monitoring defects in sheet materials due to diagonal scanning paths and standalone defect detection systems, leading to difficulties in real-time analysis and higher production of defective batteries.
Innovation Solution
An integrated quality monitoring system that combines data from multiple sensors and cameras, using fiducial markers to align measurements and enable real-time, comprehensive defect analysis and correction across the machine and cross directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If scanning sensors are used to detect sheet properties, then measurement capability is improved, but the sensors can only measure along diagonal zig-zag paths and miss defects in areas not covered by the scan path
Solution Approach 1:
The patent combines data from multiple scanning sensors positioned at different locations to create a comprehensive defect map. By merging the measurement data from several sensors that scan different portions of the sheet, the system achieves complete coverage of the sheet surface while maintaining measurement precision.
Solution Approach 2:
The patent transitions from one-dimensional scanning measurements to two-dimensional defect mapping by integrating data from multiple sensors across different spatial positions. This dimensional transformation allows the system to reconstruct the complete sheet surface quality map, filling in gaps that individual scanning paths would miss.
2Measurement precision
If multiple discrete defect monitoring systems are used, then defect detection capability is improved, but data integration and real-time analysis become difficult
Solution Approach 1:
The patent merges data from multiple discrete monitoring systems including scanning sensors, vision systems, and quality control systems into a single integrated defect map. This consolidation allows operators to view all defect information in one unified interface, eliminating the need to analyze separate system outputs and simplifying real-time decision-making.
Solution Approach 2:
The patent creates a universal defect monitoring platform that can integrate and process data from various types of measurement systems (scanning sensors, vision systems, QCS). This multi-functional system handles different data formats and measurement types through a common processing framework, reducing overall system complexity.
3Ease of operation
If color maps are used to display measurement data, then real-time visualization is improved, but operators cannot identify specific defect types
Solution Approach 1:
The patent segments defect information into distinct categories and types within the defect map interface. By dividing the displayed data into specific defect classifications (e.g., coating defects, substrate defects, contamination), the system maintains the real-time visual appeal of color maps while providing detailed defect type identification through organized data segmentation.
Solution Approach 2:
The patent applies different display qualities and levels of detail to different regions or aspects of the defect map. Critical defect type information is highlighted with enhanced visual properties while maintaining the overall color map visualization, allowing operators to quickly identify both the location and nature of defects without losing the real-time monitoring capability.
Data Source
AI summary
Integrated quality monitoring techniques enable a plant operator to simultaneously view and analyze data that are derived from a plurality of sensors. An apparatus for and a method of inferring quality of a sheet roll consecutively monitors new data including: (a) surface defects of the sheet roll from vision defect tracking system, (b) measurement defects of the sheet roll from vision measurement system, and (c) quality and defect data of the sheet roll from quality control system, and simultaneously integrating the new data with old data in history. Data connect application programming interface can furnish historical, current and alarms data for analysis to an aggregator node for reporting and analysis.