Battery Cell Activation Tray Misalignment Detection by Distance Sensing
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Solution Overview
Problem
Existing methods fail to effectively detect misassembly and misalignment of inner trays during the activation process of battery cells, leading to potential damage such as dents, scratches, or cracks in battery cells.
Innovation Solution
Implementing distance measuring and object detection sensors on the outer tray to measure and compare distances to the inner tray's surfaces, and monitor spaces relative to a reference plane, to determine misassembly or misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inner tray and outer tray are assembled without detection, then the assembly process is simple and fast, but misassembly or misalignment may occur causing battery cell damage
Solution Approach 1:
The patent applies preliminary action by measuring the distance between the inner tray and outer tray before the battery cell insertion process begins. The distance measuring sensor detects the position relationship between trays in advance, allowing the system to identify misassembly or misalignment conditions before they can cause damage to battery cells during operation.
Solution Approach 2:
The patent implements feedback by using the distance measuring sensor to continuously monitor the position relationship between the inner tray and outer tray. The measured distance information is fed back to the control system, which can then detect abnormal changes in distance that indicate misassembly or misalignment, and trigger appropriate responses to prevent battery cell damage.
2Measurement precision
If distance measuring sensors are installed to detect misassembly, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent uses a distance measuring sensor as an intermediary device to indirectly detect the position relationship between the inner tray and outer tray. Instead of requiring direct physical measurement or complex mechanical detection mechanisms, the sensor measures the distance between the trays through electromagnetic fields or light, providing accurate detection with relatively simple device structure.
Solution Approach 2:
The patent replaces potential mechanical detection methods with a non-contact distance measuring sensor. This substitution eliminates the need for complex mechanical linkages, contact points, or physical measurement devices, thereby reducing device complexity while maintaining or improving measurement precision.
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 method reliably detects misassembly and misalignment, preventing damage to battery cells and improving the quality and productivity of secondary batteries.
Implementation Method 1
measuring a distance to one side surface of the inner tray in a longitudinal direction with the distance measuring sensor
Data Source
Figure 1
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Figure 3(a)~3(b)
AI summary
The present invention provides a method of detecting an occurrence of misassembled or misalignment of an inner tray during operation in a battery cell activation tray including an outer tray and the inner tray that is fixed to a bottom surface of the outer tray and accommodates a plurality of battery cells, and the battery cell activation tray to which the detection method is applied.