Battery Weld Seam Height Detection With Oblique Imaging
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Solution Overview
Problem
Current manual visual inspection and touch methods for detecting weld seams in battery connections are inaccurate and prone to missed defects, posing safety risks due to low efficiency and uncontrollable factors.
Innovation Solution
A welding detection apparatus and method using an obliquely positioned image acquisition component to measure the protruding height of weld seams relative to a reference surface, with a controller determining compliance with preset thresholds, and optionally dividing the seam into detection areas and fitting spatial lines to detect appearance defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection and touch are used to detect weld seams, then the detection process is simple and requires no special equipment, but the detection accuracy is low and defects are frequently missed
Solution Approach 1:
The patent replaces manual visual inspection and touch-based detection with an automated image acquisition system. The image acquisition component captures images of the weld seam, and a controller automatically analyzes these images to detect defects, substituting human mechanical inspection with an optical-mechanical detection system that provides higher accuracy and consistency.
2Measurement precision
If the image acquisition component is positioned directly above the weld seam, then the shooting path is straightforward, but the protruding height measurement accuracy is reduced due to lack of perspective
Solution Approach 1:
The patent positions the image acquisition component obliquely above the weld seam rather than directly above it, creating an asymmetric viewing angle. This oblique position allows the system to capture the protruding height of the weld seam relative to the reference surface by comparing the weld seam region with the reference surface region in the captured image, thereby improving measurement accuracy through perspective differentiation.
3Reliability
If multiple detection points are used to determine weld seam defects, then the detection coverage is improved, but the probability of false detection increases due to image acquisition component shaking
Solution Approach 1:
The patent establishes a reference surface region before weld seam detection by capturing an image of the reference surface (case outer surface) and identifying a reference line. This preliminary reference establishment allows subsequent weld seam measurements to be compared against a stable baseline, reducing false detections caused by positioning variations or component shaking while maintaining comprehensive defect coverage.
Data Source
AI summary
A welding detection apparatus is used for detecting a weld seam between a case and a top cover of a battery, and includes: an image acquisition component configured to shoot the weld seam, the image acquisition component being located obliquely above an outer side of the weld seam and forming an included angle with a height direction of the battery; and a controller configured to obtain a protruding height of the weld seam relative to a reference surface area on an outer side wall of the case according to a first distance between the image acquisition component and the outer side wall of the case, a second distance between the image acquisition component and the weld seam, and the included angle, and compare the protruding height with a preset height threshold to determine whether the protruding height of the weld seam is qualified.