Dual-Path Battery Weld Inspection for Reduced Tact Time
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Solution Overview
Problem
Existing battery inspection devices using endoscopic lenses face challenges such as limited speed, disruption of production line tact time, and risk of damage to both the battery and inspection device during the inspection process.
Innovation Solution
A battery inspection device with an upper and lower inspection unit, each equipped with a lens module and camera, and a light-path guide unit that splits incident light into two paths to allow simultaneous inspection of upper and lower weld areas without stopping the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of batteries are manually inspected one by one, then inspection thoroughness is maintained, but inspection time and labor costs increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system using cameras and image processing algorithms. The system captures images of battery surfaces and uses computer vision to detect defects, eliminating the need for manual visual inspection while maintaining high detection accuracy and enabling parallel processing of multiple batteries.
Solution Approach 2:
The patent creates visual copies (images) of the battery surfaces using cameras, and then analyzes these copies through image processing. This allows multiple batteries to be inspected simultaneously by processing their respective image copies, dramatically increasing inspection throughput while maintaining thorough defect detection through algorithmic analysis.
2Productivity
If multiple batteries are inspected in parallel, then inspection efficiency increases, but the inspection device complexity and cost increase
Solution Approach 1:
The patent employs a single multi-functional inspection device that can inspect multiple batteries simultaneously using the same camera system, lighting setup, and image processing pipeline. The system is designed to handle batches of batteries through a conveyor mechanism, allowing parallel inspection without requiring separate inspection stations for each battery, thus increasing productivity while controlling device complexity.
3Device complexity
If traditional inspection methods are used, then device simplicity is maintained, but small defects on battery surfaces are missed
Solution Approach 1:
The patent replaces simple visual inspection with an automated optical system that uses cameras and sophisticated image processing algorithms. The system captures high-resolution images and applies computer vision techniques to detect small defects that would be difficult to see with the naked eye, significantly improving detection accuracy while maintaining relatively simple hardware implementation.
Solution Approach 2:
The patent creates detailed visual copies of battery surfaces through high-resolution imaging, allowing algorithmic analysis to detect subtle defects. The image processing algorithms analyze the copied visual information to identify defects that would be imperceptible in direct viewing, enhancing detection precision without requiring complex physical inspection apparatus.
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 efficient, non-disruptive inspection of battery quality by allowing simultaneous inspection of upper and lower weld areas, reducing tact time and minimizing the risk of damage to the battery and inspection device.
Implementation Method 1
a beam splitter configured to split the incident light into the first light and the second light
Implementation Method 2
a reflective mirror configured to refract the first light toward the first lens module
Implementation Method 3
a first lens module configured to condense first light
Implementation Method 4
a second lens module configured to condense second light
Data Source
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AI summary
A battery inspection device according to the present disclosure may include: an upper inspection unit including a first lens module configured to condense first light and a first camera mounted on the top of the first lens module; a lower inspection unit disposed horizontally to be spaced apart from the first lens module and including a second lens module configured to condense second light incident from an inspection object and a second camera mounted on the top of the second lens module; and a light-path guide unit integrally coupled to the first lens module and the second lens module and configured to split incident light incident from the inspection object into the first light and the second light, guide the first light to the first lens module, and guide the second light to the first lens module.