Structured Light Weld Inspection for Battery Cell Corner Defects
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Solution Overview
Problem
In high-speed production environments, the low resolution of 3D laser cameras used for welding defect detection in battery cells leads to inaccurate weld defect identification due to high scanning speeds and low image resolution, often resulting in missed defects at weld corners.
Innovation Solution
Employing a detection method that utilizes multiple structured light cameras positioned symmetrically around the battery cell to capture high-resolution images of weld seams, avoiding field-of-view overlap and ensuring complete imaging of welds, thereby improving detection precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a 3D laser camera is used for welding defect detection, then the detection system can operate in high-speed production environments, but the image resolution becomes low leading to inaccurate weld defect identification
Solution Approach 1:
The patent divides the detection system into multiple structured light cameras (2N first structured light cameras on long sides, 2M second structured light cameras on short sides) positioned at different locations. Each camera captures images of specific weld sections, and the results are integrated to achieve complete high-resolution weld detection without requiring high scanning speeds
Solution Approach 2:
The patent replaces the mechanical scanning system (3D laser camera that requires high-speed scanning) with a multi-camera static imaging system. Structured light cameras project light patterns and capture images directly without mechanical scanning, eliminating the trade-off between scanning speed and resolution
2Reliability
If multiple structured light cameras are positioned symmetrically around the battery cell, then complete imaging of welds is achieved, but the complexity of the detection device increases
Solution Approach 1:
The patent positions structured light cameras asymmetrically relative to the battery cell's weld seams. The cameras are placed at specific angles and distances to optimize field-of-view coverage of weld areas while avoiding symmetric arrangements that would create light interference. This asymmetric positioning achieves complete weld imaging with reduced device complexity
3Area of stationary object
If structured light cameras capture images with wide angle-of-view, then complete weld coverage is achieved, but interference between structured light beams increases
Solution Approach 1:
The patent assigns different local functions to different cameras based on their positions. Each structured light camera is configured with specific projection patterns and viewing angles optimized for its local weld section. This localized optimization allows wide angle-of-view coverage while minimizing light beam interference through spatial separation and directional control
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 enhances the detection precision of weld defects by capturing high-resolution images with a wide angle-of-view, effectively reducing interference between structured light beams and preventing R corner loss, thus improving the accuracy of weld defect detection in high-speed production.
Implementation Method 1
acquiring a first shot image of a long-side weld of the battery cell under detection by using a first structured light camera on the long side of the battery cell under detection
Data Source
AI summary
A detection method includes acquiring a first shot image of a long-side weld of a battery cell under detection by using a first structured light camera on a long side of the battery cell under detection, acquiring a second shot image of a short-side weld of the battery cell under detection by using a second structured light camera on the short side of the battery cell under detection, detecting a defect of the long-side weld of the battery cell under detection based on the first shot image, and detecting a defect of the short-side weld of the battery cell under detection based on the second shot image.