Battery Tab Misalignment Detection During Electrode Plate Winding
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Solution Overview
Problem
The production of lithium batteries with misaligned battery tabs is a significant issue, as misalignment can occur during the winding process and is not detected until after pressing, leading to defective battery cells.
Innovation Solution
A misalignment detection method and apparatus that uses a winding shaft to capture images of electrode plate sections, determining the relative positional relationship between battery tabs and a reference part to predict misalignment before pressing, utilizing a line scan camera and stitching multiple image rows for high-resolution imaging, and calculating misalignment based on layer thickness and radius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If misalignment detection is performed only after the pressing process, then the detection is simple and late-stage, but multiple electrode plates have already been wound and all may have defective misaligned tabs
Solution Approach 1:
The patent performs misalignment detection during the winding process itself, before the pressing operation occurs. The detection system captures images of battery tabs at different winding layers and calculates misalignment amounts in advance, enabling early identification of defective electrode plates before they are wound into the final battery cell structure.
Solution Approach 2:
The patent replaces traditional mechanical detection methods with an optical imaging system. A camera captures images of battery tabs during winding, and a processor analyzes these images to determine misalignment amounts, substituting physical contact-based detection with non-contact optical measurement.
2Measurement precision
If high-resolution imaging is used to accurately detect misalignment, then detection precision is improved, but device complexity increases due to line scan camera and image stitching requirements
Solution Approach 1:
The patent divides the imaging process into multiple segments by capturing images layer by layer during the winding process. Instead of requiring a single complex high-resolution capture, the system takes multiple images at different winding stages and processes them sequentially to determine misalignment amounts.
Solution Approach 2:
The patent adds the time dimension to the imaging process by capturing images at different moments during winding. Rather than attempting to capture all information simultaneously in a single complex image, the system uses temporal sequencing of simpler images taken as the electrode plate winds through the detection zone.
Data Source
AI summary
A misalignment detection method and apparatus for battery tabs, and a battery electrode plate winding system, are disclosed. The method includes winding a battery electrode plate onto a winding shaft. For an Nth layer (where N is an integer greater than zero) of the electrode plate section wound on the winding shaft, an image including a battery tab region is acquired during the winding period. A relative positional relationship between a battery tab and a reference part on the winding shaft is determined from the image. Based on this positional relationship and the layer number of the Nth electrode plate section, a misalignment amount of the battery tab is calculated for when the wound electrode plate is later pressed into a battery cell. The method enables real-time monitoring of tab alignment during winding, improving accuracy in battery cell assembly.