Battery Cell Tab Height Sensing for Space-Constrained Inspection
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Solution Overview
Problem
Existing methods for detecting abnormal states of battery cells, such as lifted or sagging tabs, during modularization are inaccurate due to reliance on visual inspection and lack of clear criteria, especially when space constraints limit the installation of lighting and camera systems around battery terminals.
Innovation Solution
A method and device using an image acquisition unit on a mounting unit to acquire images of battery cells, extracting height information of tabs relative to the mounting unit, and analyzing this information to determine the state of the battery cells, including whether tabs are lifted or normally positioned, employing 3D imaging and preset ranges for accurate assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If lighting and camera are disposed horizontally around the battery terminal to detect tab height, then measurement precision is improved, but device complexity and space requirements increase due to mounting constraints
Solution Approach 1:
The patent transitions from horizontal arrangement of lighting and camera to a vertical arrangement where the image acquisition unit is disposed on the upper surface of the mounting unit. This dimensional change allows the system to capture top-down images of the battery terminal and tab, enabling height measurement without requiring lateral space around the terminal.
Solution Approach 2:
The patent uses optical imaging to create a visual copy of the battery terminal and tab structure. By capturing an image from above and analyzing the pixel coordinates and intensity values, the system indirectly measures tab height without requiring physical contact or complex mechanical measurement devices.
2Productivity
If worker performs visual inspection during battery cell transport, then inspection coverage is improved, but measurement precision and reliability deteriorate due to difficulty in quantifying inspection criteria
Solution Approach 1:
The patent replaces the human visual inspection system with an automated image acquisition and analysis system. The controller automatically processes images to extract tab height information by analyzing pixel coordinates and intensity values, eliminating subjectivity and enabling precise, quantifiable measurements while maintaining high inspection coverage.
Solution Approach 2:
The system provides automated feedback by analyzing the captured images and determining whether the battery cell is normally disposed or abnormal based on calculated tab height. This feedback mechanism replaces subjective worker judgment with objective, criterion-based automated decision-making.
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 accurate detection of battery cell states, including lifted or sagging tabs, and proper alignment, improving the accuracy and clarity of inspections, even in space-constrained environments, by utilizing 3D imaging and preset criteria for determining normal or abnormal states.
Implementation Method 1
an image acquisition unit on an upper part of a mounting unit on which the battery cell is disposed, acquires an image of the mounting unit and the battery cell
Data Source
AI summary
A device and method of sensing a state of a battery cell disposed on a mounting unit are disclosed. The method includes an image acquisition step of acquiring, by an image acquisition unit on an upper part of a mounting unit on which the battery cell is disposed, an image of the mounting unit and the battery cell, a height information extraction step of extracting, by a controller, height information of a tab included in the battery cell with respect to a point of the mounting unit from the image, and a battery cell state analysis step of determining, by the controller, a state of the battery cell based on the height information.