Battery Module Weld Inspection Using Force and Vision Feedback
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Solution Overview
Problem
Conventional human visual and machine vision inspection methods for battery module welding are inadequate as they cannot detect defects like gaps, insufficient depth, or excessive internal pores in the weld, leading to reliability issues and increased labor costs due to manual processes.
Innovation Solution
An automated welding inspection system that includes a frictional reaction force measurement unit and a vision inspection camera to determine the quality of welds by measuring frictional reaction forces and position changes of the battery module's lead, using a servo plate and rail system for precise movement and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional human visual inspection or machine vision inspection is used to inspect the exterior of the battery cell, then the length, width, and penetration of the weld bead can be checked, but it is impossible to detect welding defects occurring in the base material such as gaps, insufficient depth, or excessive internal pores
Solution Approach 1:
The patent replaces the conventional optical/machine vision inspection system with a mechanical testing system. A testing probe applies controlled mechanical force to the weld bead, and the reaction force is measured to detect internal defects. This mechanical approach substitutes the optical field with a mechanical field, enabling detection of subsurface defects that optical methods cannot detect.
Solution Approach 2:
The patent introduces a testing probe as an intermediary between the inspection system and the weld bead. The probe transmits mechanical force into the weld bead and transmits the reaction force back to the measurement system, serving as a mediator that enables indirect detection of internal defects through mechanical interaction rather than direct optical observation.
2Ease of operation
If manual inspection by workers is performed, then the inspection process can be conducted, but each worker has different technical skill thereby lowering reliability, and labor cost increases due to manual process
Solution Approach 1:
The patent implements an automated testing system that performs inspection without human intervention. The system autonomously positions the testing probe, applies force, measures reaction forces, and determines weld quality. This self-service automation eliminates dependence on worker skills and ensures consistent, reliable inspection results.
Solution Approach 2:
The patent replaces the manual human inspection process with an automated mechanical testing system. The mechanical system objectively measures weld properties through controlled force application and reaction force measurement, substituting subjective human judgment with objective mechanical measurement to improve reliability and reduce labor costs.
3Device complexity
If conventional inspection methods are used, then the inspection process is simple, but they cannot detect internal welding defects leading to quality issues
Solution Approach 1:
The patent replaces simple optical inspection equipment with a more complex mechanical testing system that includes a force application mechanism and reaction force measurement capability. This increased device complexity enables the system to detect internal welding defects through mechanical interaction, thereby improving manufacturing precision and weld quality assurance.
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 system effectively prevents human error and inspection omissions, reduces labor costs, and improves welding quality by detecting poor welds, such as non-welding or weak welding, while avoiding damage from conventional inspection methods.
Implementation Method 1
a frictional reaction force measurement unit inducing a slight movement of the welded portion of the battery module and measuring a frictional reaction force generated thereby
Data Source
AI summary
Provided is a system for detecting a poor weld in a welded portion of a battery module, the system including a battery module fixation unit fixing the battery module to be inspected, an inspection position movement unit moving the battery module fixation unit to a welding inspection position, a welding inspection unit including a frictional reaction force measurement unit inducing a slight movement of the welded portion of the battery module and measuring a frictional reaction force generated thereby and a vision inspection camera detecting an amount of change in a position of the welded portion of the battery module, and a control unit determining whether the welded portion of the battery module is poorly welded based on the frictional reaction force and the amount of position change, measured by the welding inspection unit.