Battery Tab Vision Inspection for Folding Area Detection
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Solution Overview
Problem
Conventional tab detection systems in battery production cannot accurately detect tab folding, leading to safety hazards such as short circuits and lithium precipitation.
Innovation Solution
A tab detection system comprising an image acquisition module and an upper-level controller that acquires images of tabs after die cutting and rolling, allowing for accurate detection of tab folding and residual materials by comparing image data with preset parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photoelectric sensors are used for tab detection, then the detection process can be implemented, but the detection accuracy is insufficient and cannot measure folding area
Solution Approach 1:
The patent replaces photoelectric sensors with a vision detection system comprising an image acquisition module (camera) and processing unit. This substitution enables accurate measurement of tab folding areas by capturing images and analyzing pixel data, transforming the detection method from simple presence detection to quantitative measurement capability.
Solution Approach 2:
The patent changes the detection parameter from binary detection (folded/not folded) to continuous measurement by calculating the area of folded regions through image processing. The system computes the number of pixels representing folded areas and compares them against threshold values, enabling precise quantification of folding severity.
2Reliability
If photoelectric sensors are used for tab detection, then detection can be performed, but the system is easily interfered by light causing missed detection
Solution Approach 1:
The patent replaces photoelectric sensors that are susceptible to light interference with a vision system using image capture and digital processing. The image acquisition module captures visual information that can be processed algorithmically, making the system immune to ambient light conditions that would interfere with photoelectric detection.
Solution Approach 2:
The patent creates a digital copy of the tab structure through image capture, allowing analysis of the copied visual data rather than direct optical measurement. This copying approach enables post-processing and analysis without real-time light interference, as the image data can be processed independently of ambient lighting conditions.
3Loss of time
If tabs are detected after battery cell formation, then detection is possible, but tab folding cannot be prevented during subsequent processes
Solution Approach 1:
The patent implements detection at an intermediate stage in the production process, after die cutting and rolling but before lamination and final assembly. This preliminary detection allows identification and removal of defective tabs before they cause problems in subsequent processes, preventing safety hazards while maintaining production efficiency.
Solution Approach 2:
The system provides real-time feedback on tab quality by analyzing images and determining whether tabs are properly formed. This feedback mechanism enables immediate identification of folding defects, allowing for corrective action or rejection of defective products before they proceed to later production stages where they could cause safety issues.
Data Source
AI summary
This application relates to a tab detection system and a tab detection method. The system includes an image acquisition module and an upper-level controller. The image acquisition module is configured to acquire an image of a tab of a battery cell rolled by a die cutting module, where the image acquisition module is located between the die cutting module and a lamination module. The upper-level controller is configured to determine whether the tab has a defect based on the image of the tab.