Battery Assembly Welding Position Recognition Under Surface Noise
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Solution Overview
Problem
The challenge in manufacturing battery assemblies is the difficulty in recognizing the welding area due to noise factors like scratches and foreign substances, leading to reduced facility utilization, welding quality, and increased risk of defects and fires.
Innovation Solution
A welding position recognition apparatus with a photographing unit, moving unit, and control unit that performs first and second photographings to select a reference point, adjust recognition areas, and correct for manufacturing tolerances to improve welding position recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single photographing is performed to capture the welding area, then the photographing process is simple and fast, but noise factors such as scratches and foreign substances cannot be effectively distinguished from the welding area
Solution Approach 1:
The photographing process is divided into multiple sequential photographings (first photographing, second photographing, and optionally third photographing) with different recognition areas. The control unit processes each photographing result separately and combines them to identify the welding area, thereby improving recognition accuracy by segmenting the detection process into distinct stages with different focal points.
Solution Approach 2:
The first photographing is performed to capture an initial image of the workpiece surface before subsequent photographings. This preliminary photographing establishes a baseline image that the control unit uses to identify noise factors and differentiate them from actual welding areas in subsequent images, enabling more accurate welding area recognition.
2Reliability
If multiple photographings are performed with different recognition areas to improve welding area recognition, then welding quality improves, but the photographing time and processing complexity increase
Solution Approach 1:
The recognition area is dynamically adjusted between different photographings. The control unit sets different recognition areas for the first, second, and third photographings based on the specific features being detected. This dynamic adjustment allows the system to capture comprehensive information efficiently while maintaining high welding area recognition accuracy, thereby improving welding quality without excessive time loss.
Solution Approach 2:
The control unit processes the results of each photographing and uses this feedback to determine the welding area. By analyzing the first photographing result, then the second photographing result, and optionally the third photographing result in sequence, the control unit refines its identification of the welding area, improving welding quality through iterative feedback processing while managing time efficiency.
3Measurement precision
If the recognition area is set to cover the entire workpiece surface, then all potential welding areas are captured, but noise factors occupy a larger portion of the image reducing recognition accuracy
Solution Approach 1:
Different recognition areas are applied to different photographings based on local features of the workpiece. The first photographing uses a first recognition area, the second photographing uses a second recognition area, and the third photographing uses a third recognition area. Each recognition area is optimized for detecting specific local features, which improves welding area identification accuracy by focusing on relevant regions rather than uniformly covering the entire surface.
Solution Approach 2:
The system approaches welding area recognition from multiple dimensional perspectives by performing photographings with different recognition areas and combining the results. This multi-dimensional approach allows the control unit to distinguish welding areas from noise factors more accurately by analyzing the same workpiece surface through different recognition area dimensions, thereby improving identification accuracy without requiring excessive area coverage in any single photographing.
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
Enhances manufacturing efficiency by improving welding quality and reducing noise factors, thereby preventing defects and fires in battery assembly processes.
Implementation Method 1
a recognition sensor recognizing reflected light of irradiated light reflected on the surface of the battery assembly
Data Source
AI summary
The present disclosure relates to a welding position recognition apparatus for a battery assembly and a method using the same. The welding position recognition apparatus for the battery assembly according to embodiments of the present disclosure comprises a photographing unit spaced apart from the battery assembly to photograph a surface of the battery assembly including an area to be welded, a moving unit connected to the photographing unit and horizontally moving in parallel with the surface of the battery assembly, and a control unit controlling the photographing unit and the moving unit, wherein the control unit performs: first photographing of a portion of the surface of the battery assembly by the photographing unit to select a reference point, and second photographing of the surface of the battery assembly spaced apart from the reference point by a correction distance by the photographing unit.