Battery Tab-Lead Inspection Using Eddy Current Impedance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for inspecting the tab-lead connecting portion of secondary batteries are inefficient and inaccurate, leading to potential electrical instability and separation issues, and there is a need for a rapid and non-destructive method to assess the physical and electrical connection conditions.
Innovation Solution
A method using an eddy current sensor to induce and measure impedance in the battery's metal portions, applying a discriminant function to analyze the condition of the tab-lead connection, utilizing multiple AC currents at different frequencies to accurately judge the connection state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for tab-lead connecting portion, then inspection can be performed, but inspection speed is slow and accuracy is insufficient
Solution Approach 1:
The patent replaces traditional mechanical contact-based inspection methods with eddy current sensing technology. The eddy current sensor non-contactively detects the tab-lead connecting portion by generating electromagnetic fields, eliminating mechanical contact while achieving both high-speed and high-precision inspection capabilities suitable for automated production lines.
Solution Approach 2:
The patent utilizes changes in eddy current sensor output impedance as the inspection parameter. By monitoring impedance variations caused by defects in the tab-lead connection, the system achieves rapid and accurate detection without mechanical contact, resolving the contradiction between inspection speed and accuracy.
2Productivity
If eddy current sensor is used to inspect metal portion, then inspection speed increases, but measurement accuracy may be affected by complex impedance factors
Solution Approach 1:
The patent introduces a signal processing system as an intermediary between the eddy current sensor and the final inspection result. The system processes the complex impedance output by calculating resistance and reactance components, and compares them against reference values to accurately determine the presence of defects, thereby maintaining measurement accuracy while achieving high-speed inspection.
Solution Approach 2:
The patent implements a feedback mechanism where the eddy current sensor output is continuously monitored, processed, and compared against predetermined reference values. This feedback loop enables real-time accurate measurement by adjusting for variations in the complex impedance signal, maintaining precision while enabling rapid inspection.
3Reliability
If non-destructive inspection method is applied, then battery integrity is maintained, but inspection capability for physical and electrical problems needs to be enhanced
Solution Approach 1:
The patent replaces destructive mechanical inspection methods with non-contact eddy current sensing. The eddy current sensor detects both physical defects (such as cracks or discontinuities) and electrical problems (such as poor connections) in the tab-lead connecting portion without damaging the battery, thereby maintaining battery integrity while enhancing comprehensive detection capability.
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 quick and precise inspection of the battery's metal portions without damage, suitable for mass production lines, ensuring reliable electrical connections.
Implementation Method 1
an eddy current induction step of 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
an output voltage measurement step of 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
Figure 1
Figure 2
Figure 3
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.