Eddy Current Battery Tab Inspection for Fast Weld Quality Screening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for a method to quickly and accurately inspect the physical and electrical conditions of the metal portion in battery tab-lead connecting portions, as abnormal welding processes can lead to unstable electrical connections and potential separation of electrode leads and tabs, especially under shock or vibration.
Innovation Solution
The method employs an eddy current sensor to induce an AC current in the battery's metal portion, measuring the resulting impedance and applying it to a discriminant function to determine the condition of the metal portion, allowing for non-destructive testing and accurate judgment of the connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used to detect welding quality in battery tab-lead connecting portions, then measurement precision can be achieved, but inspection speed is slow and productivity is reduced
Solution Approach 1:
The patent replaces traditional mechanical contact-based welding inspection methods with an eddy current sensing system. The eddy current sensor non-contactively detects welding quality by measuring impedance changes in the metal portion, eliminating the need for physical contact and enabling faster inspection while maintaining measurement precision.
Solution Approach 2:
The patent utilizes changes in electrical impedance parameters of the metal portion to detect welding quality. By monitoring impedance variations caused by eddy currents in different welding conditions, the system achieves both high measurement precision and fast inspection speed through non-contact electrical parameter measurement.
2Reliability
If non-destructive testing methods are applied to inspect battery metal portions, then the battery remains undamaged and full inspection is enabled, but the complexity of the inspection system increases
Solution Approach 1:
The patent replaces complex mechanical disassembly and contact-based inspection systems with a simplified eddy current sensing system. The non-contact electromagnetic inspection method maintains battery integrity while reducing mechanical complexity through direct electrical impedance measurement of the metal portion.
Solution Approach 2:
The eddy current sensor utilizes the battery's own metal portion as the sensing path, making the battery structure itself serve the inspection function. This self-service approach reduces external inspection equipment complexity while ensuring the battery remains undamaged during inspection.
3Productivity
If eddy current sensing is used to quickly inspect battery metal portions, then productivity increases and full inspection is enabled, but measurement precision and discrimination of connection quality become more difficult
Solution Approach 1:
The patent replaces slow mechanical inspection methods with eddy current sensing that measures electrical impedance. This substitution enables rapid full inspection while achieving high measurement precision through the sensitivity of eddy current impedance to welding quality variations in the metal portion.
Solution Approach 2:
The patent exploits impedance parameter changes in the metal portion that occur with different welding qualities. By measuring real and imaginary parts of impedance and applying discriminant analysis, the system achieves both fast inspection and accurate discrimination of connection quality through electrical parameter variations.
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
This approach enables quick and accurate analysis of the metal portion's condition, suitable for mass production lines, ensuring full inspection without damaging the batteries and distinguishing between normal and defective connections effectively.
Implementation Method 1
inputting an input current that is an AC current into a transmission coil and irradiating a primary magnetic field generated in the transmission coil to a metal portion of the battery to induce an eddy current in the metal portion of the battery
Implementation Method 2
induce an eddy current in the metal portion of the battery; inputting a secondary magnetic field generated by the eddy current generated in the eddy current induction step into a receiving coil and measuring an induced electromotive force in the receiving coil generated by the secondary magnetic field
Data Source
AI summary
The present invention relates to a big data-based battery inspection method. Specifically, the present invention is for providing a big data-based battery inspection method which applies information on a metal part of a battery measured by an eddy current sensor to a discrimination function so as to quickly inspect the state of the metal part.