Battery Tab Cross-Section Analysis for Folded Layer Inspection
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Solution Overview
Problem
Current methods for inspecting battery tabs during the winding process of traction batteries are inefficient and prone to missed inspections, particularly when tabs are folded into the electrode plate, leading to potential short circuits and thermal runaway.
Innovation Solution
A method and apparatus that analyze sectional views of battery tabs to identify connected domains and intersection points, allowing for accurate calculation of tab layers and automatic detection of folded tabs, thereby improving inspection efficiency and reducing missed inspection rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual visual inspection is used to detect folded tabs, then the inspection method is simple to implement, but the inspection efficiency is low and the missed inspection rate is high
Solution Approach 1:
The patent replaces manual visual inspection with an automated image processing system that captures images of battery tabs and uses algorithmic analysis to detect folding defects. This substitution of mechanical/manual inspection with an automated optical-electronic system directly resolves the contradiction by dramatically improving inspection efficiency while maintaining implementation feasibility through software-based solutions.
Solution Approach 2:
The patent creates a digital copy (image) of the battery tab structure and performs inspection on this copy rather than requiring direct manual examination of the physical tab. By working with image data and applying processing algorithms to the copy, the system achieves high-speed automated inspection without the limitations of manual visual methods.
2Measurement precision
If Hi-pot testing is used to detect folded tabs, then the inspection rate is high for tabs folded onto separator, but it cannot identify tabs folded into electrode plate layers
Solution Approach 1:
The patent transitions from electrical resistance measurement (single-dimensional Hi-pot testing) to multi-dimensional image analysis that examines spatial relationships, layer positions, and geometric configurations. By adding spatial and structural dimensions to the detection process, the system can identify both separator folds and electrode plate folds that were invisible to electrical testing alone.
Solution Approach 2:
The patent segments the battery structure into distinct components (tabs, separator, electrode plates) and analyzes their spatial relationships independently. By dividing the inspection task into component-specific analysis and examining how these segments relate to each other in the image data, the system achieves comprehensive detection across all fold types with high precision and versatility.
3Ease of manufacture
If the metal foil tab is reserved for current passage, then the battery structure is simplified for manufacturing, but the thin and weak tab is prone to folding during winding
Solution Approach 1:
The patent performs preliminary action by implementing automated inspection that detects tab folding defects before they cause failure. By capturing images and analyzing tab positions during or after the winding process, the system identifies folded tabs early, allowing for corrective action before the defective battery proceeds to subsequent manufacturing steps or reaches the customer.
Solution Approach 2:
The patent establishes a feedback mechanism where image analysis results provide real-time information about tab conditions, which can be used to adjust manufacturing parameters or reject defective units. This closed-loop feedback system maintains reliability by continuously monitoring tab integrity while preserving the manufacturing simplicity of the winding process.
Data Source
AI summary
The present application discloses a method for inspecting a battery tab, the method including: obtaining a sectional view of a plurality of layers of tabs of a battery; identifying and analyzing the sectional view to obtain a plurality of connected domains, where each connected domain includes one tab or a plurality of tabs that are bonded with each other; determining, based on positions and a number of intersection points of tab bonding in each connected domain, a number of layers of tabs corresponding to the connected domain; calculating a total number of layers of the plurality of layers of tabs in the sectional view based on the number of layers of tabs corresponding to the connected domain; and determining, based on the total number of layers of tabs and a preset real number of layers of tabs, whether the plurality of layers of tabs are folded.