Battery Cover Welding Calibration for Optical Fault Inspection
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Solution Overview
Problem
Existing battery housing cover welding systems face challenges in ensuring stable and reliable operation, leading to potential faults and defects due to issues like damaged light sources, contaminated lenses, and loose cable connections, which are difficult to detect and correct efficiently.
Innovation Solution
A battery housing cover welding system equipped with a calibration block featuring specific surface and side surface features, multiple cameras, and a host computer to analyze images for fault detection, reducing manual intervention and improving accuracy and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual checking methods are used for the battery housing cover welding system, then operational flexibility is maintained, but checking speed and accuracy deteriorate due to human error and slow inspection processes
Solution Approach 1:
The patent replaces manual mechanical checking with an automated optical inspection system comprising multiple cameras positioned at different angles, lighting assemblies, and a host computer for image processing. This substitution eliminates human error and significantly increases checking speed while maintaining high accuracy through automated defect detection algorithms.
Solution Approach 2:
The system creates multiple optical copies (images) of the battery housing cover from different perspectives using several cameras simultaneously. These copied images are then processed by the host computer to comprehensively detect defects, achieving both high speed and high accuracy through parallel image acquisition and analysis.
2Reliability
If comprehensive fault detection is implemented to improve reliability, then system stability improves, but device complexity increases due to multiple cameras, calibration blocks, and processing systems
Solution Approach 1:
The inspection system is segmented into distinct functional modules: multiple cameras for different viewing angles, separate lighting assemblies for various illumination needs, a calibration block for standardized reference, and a host computer for centralized processing. This segmentation allows each component to be optimized independently while working together to achieve comprehensive fault detection with high reliability.
Solution Approach 2:
The host computer serves multiple functions: acquiring images from all cameras, processing and analyzing the images, comparing detected features against calibration data, identifying defects, and controlling the overall inspection process. This multi-functionality reduces the need for separate dedicated devices, managing system complexity while maintaining comprehensive detection capabilities.
3Measurement precision
If multiple cameras and calibration blocks are added to improve measurement accuracy, then checking precision improves, but device complexity and initial cost increase
Solution Approach 1:
The system transitions from single-point or single-angle inspection to multi-dimensional inspection by positioning cameras at different spatial angles and heights. The calibration block provides reference features in multiple dimensions (top surface, side surfaces, edges), enabling three-dimensional defect detection and significantly improving measurement accuracy through comprehensive geometric coverage.
Solution Approach 2:
Multiple cameras, lighting assemblies, and the calibration block are merged into an integrated inspection system controlled by a single host computer. This consolidation allows synchronized operation of all components, efficient use of shared resources (processing power, data storage), and coordinated defect detection, managing overall system complexity while achieving high detection 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 system enables timely detection and correction of faults, enhancing measurement accuracy and reliability, improving production efficiency by reducing human error and increasing check speed.
Implementation Method 1
a first camera, a second camera, a third camera, and a fourth camera, where the first camera is located diagonally above the first edge and used to acquire check images of the first surface feature and the first side surface feature
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present application provides a battery housing cover welding system and a point check method for same. The system includes a calibration block including a battery profiling body which includes: a top surface, a first side surface joined to the top surface through a first edge, a second side surface joined to the top surface through a second edge, a third side surface joined to the top surface through a third edge, and a fourth side surface joined to the top surface through a fourth edge; a first surface feature, a second surface feature, a third surface feature, and a fourth surface feature that are disposed near the first edge, the second edge, the third edge, and the fourth edge, respectively, and all located on the top surface; and a first side surface feature, a second side surface feature, a third side surface feature, and a fourth side surface feature that are disposed near the first edge, the second edge, the third edge, and the fourth edge, respectively, and located on the first side surface, the second side surface, the third side surface, and the fourth side surface, respectively. The technical solution of embodiments of the present application may enable the determining of whether the battery housing cover welding system has a fault.