Battery Tab Inspection With Closed-Loop Prism Adjustment
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Solution Overview
Problem
Existing battery cell tab detection systems require manual adjustment of prism position to obtain clear images, which is time-consuming and subjective, making it difficult to achieve accurate and automated tab imaging.
Innovation Solution
A tab detection system with a control unit that automatically adjusts a movable prism unit to optimize image capture, using evaluation parameters to determine if the image quality meets a threshold, and includes features like automatic cleaning and shock absorption to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment of prism position is used to obtain clear tab images, then image quality can be improved, but adjustment time and labor costs increase significantly
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated control system that uses motors to drive the prism table and imaging unit. The control system automatically calculates and adjusts positions based on evaluation parameters, eliminating the need for manual mechanical adjustment while maintaining image quality.
Solution Approach 2:
The system performs self-adjustment through automatic control. The control unit automatically evaluates image quality using evaluation parameters, determines whether adjustment is needed, and drives the prism table and imaging unit to optimal positions without human intervention, enabling the system to serve itself.
2Measurement precision
If manual adjustment of prism position is used, then image clarity can be achieved, but operational complexity and subjectivity increase
Solution Approach 1:
The patent replaces subjective manual judgment with objective automated image quality evaluation. The control unit calculates evaluation parameters from captured images and automatically determines whether the image meets quality standards, eliminating operator subjectivity and simplifying operation.
Solution Approach 2:
The system implements automatic feedback control by evaluating image quality parameters and using this information to drive further adjustments. The control unit continuously monitors image quality and adjusts the prism table and imaging unit positions based on evaluation results, creating a closed-loop system that simplifies operation while ensuring image clarity.
3Productivity
If automated image evaluation and prism adjustment system is implemented, then adjustment speed and objectivity are improved, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions: capturing images, calculating evaluation parameters, determining adjustment needs, and driving the prism table and imaging unit. This multi-functional design consolidates complexity into a single control unit, improving productivity while managing system complexity through functional integration.
Solution Approach 2:
The patent merges the image capture function, evaluation function, and adjustment control function into an integrated automated system. The control unit combines these previously separate operations, and the prism table and imaging unit are merged into a coordinated adjustment mechanism, reducing overall system complexity while enhancing productivity.
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 system enables quick and automatic acquisition of clear tab images without manual intervention, improving efficiency and reducing labor costs by optimizing prism positioning and maintaining image quality.
Implementation Method 1
the prism unit, configured to project the tab image to the imaging unit through refraction
Data Source
Figure 1A~1C
Figure 1D~1F
Figure 1G~1H
AI summary
A tab detection system and a tab detection method are provided. The tab detection system includes: a control unit; an imaging unit; and a prism device, where the prism device includes: a prism table; a prism unit; and a driving unit, configured to enable the prism unit to move and/or rotate relative to the prism table, where the control unit iteratively performs the following operations until it is determined that a difference between an evaluation parameter of a tab image and a first threshold is not outside a predetermined range: sending a photographing control signal to the imaging unit; calculating the tab image to obtain the evaluation parameter; and in response to determining that the difference between the evaluation parameter and the first threshold is outside the predetermined range, enabling the prism unit to move and/or rotate at a specified step length relative to the prism table.