Battery Tab Detection Optics for Complete Side-Surface Imaging
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Solution Overview
Problem
Existing tab detection methods in battery production, particularly for traction batteries, suffer from low efficiency and high false detection rates due to reliance on manual visual inspection, which affects the quality of batteries.
Innovation Solution
A tab detection mechanism comprising a visual camera, prism, and drive member that allows for automatic detection by reflecting light on the tab portion's side surface and enabling vertical movement of the camera to capture multiple images, along with a telecentric lens for precise imaging, and a prism to adjust the view field direction, ensuring complete image acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual visual inspection is used to detect tab portions, then detection flexibility is maintained, but detection efficiency is low and false detection rate is high
Solution Approach 1:
The patent replaces manual visual inspection with an automated machine vision system consisting of a visual camera, prism, and drive member. This substitution eliminates human error and inconsistency, achieving both high detection efficiency and low false detection rate through automated image capture and analysis of the tab portion.
Solution Approach 2:
The detection system captures images automatically through the drive member moving the camera, and the visual camera itself performs the detection function without requiring manual operation. The system serves itself by integrating the imaging and detection functions into one automated unit.
2Measurement precision
If visual camera is placed horizontally to detect tab portion, then detection accuracy is improved, but space requirement increases and arrangement becomes difficult
Solution Approach 1:
The patent changes the spatial arrangement by placing the visual camera vertically rather than horizontally, and uses a prism to redirect light at 45 degrees. This dimensional change allows the camera to be positioned in a compact vertical space while still achieving accurate detection of the tab portion through optical redirection.
Solution Approach 2:
The prism acts as an intermediary between the vertically positioned camera and the horizontally oriented tab portion. It redirects light from the tab to the camera, enabling the camera to detect the tab accurately without requiring direct horizontal alignment, thus simplifying the overall arrangement.
3Speed
If single image capture is used for tab detection, then detection speed is improved, but image completeness is insufficient
Solution Approach 1:
The drive member preliminarily positions the camera at multiple locations along the vertical direction before image capture. This preliminary positioning ensures that the camera captures complete images of the entire tab portion by acquiring multiple images at different positions, which are then synthesized for comprehensive detection.
Solution Approach 2:
The detection process is segmented into multiple image captures at different vertical positions. Instead of attempting to capture the entire tab in one image, the system divides the detection into multiple stages, capturing images at different locations and then combining them to form a complete view of the tab portion.
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 mechanism enhances detection efficiency and accuracy by allowing for automatic, comprehensive, and precise imaging of tab portions, reducing false detections and improving battery quality.
Implementation Method 1
a prism, disposed below the visual camera and configured to reflect light on a side surface of the tab portion to the visual camera
Data Source
AI summary
This application discloses a tab detection mechanism and a tab detection device. The tab detection mechanism may be configured to detect a tab portion on an electrode core. The tab detection mechanism may include a visual camera; a prism disposed below the visual camera and configured to reflect light on a side surface of the tab portion to the visual camera; and a first driver, connected to the visual camera and configured to drive the visual camera to move in a vertical direction. The visual camera is capable of shooting a plurality of images while moving.