Camera Pixel Calibration Apparatus for Battery Winding Offset
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Solution Overview
Problem
Existing visual detection devices in battery manufacturing lack reliable anti-offset measures, leading to measurement errors and production inefficiencies due to camera misalignment during the winding process.
Innovation Solution
A camera pixel calibration apparatus is introduced, featuring a camera with a shooting lens and a reference assembly comprising a bracket and a calibration plate. This assembly prevents camera offset and automatically calibrates pixel accuracy, ensuring consistent detection and improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual detection is used to monitor coating material parameters, then detection speed and accuracy are improved, but camera offset due to vibration or cleaning causes measurement errors and production inefficiency
Solution Approach 1:
A transparent protective plate is introduced as an intermediary component between the camera and the coating material. This plate serves as a stable reference surface that does not vibrate or move with the coating material, providing a consistent reference frame for pixel calibration while protecting the camera from direct exposure to vibrations and cleaning operations
Solution Approach 2:
The patent creates a reference copy of the coating material's reference line on the transparent protective plate. This reference line is imprinted or drawn on the plate at a known position, creating a stable copy that can be used for continuous pixel calibration without requiring direct contact with the moving coating material
2Measurement precision
If manual pixel calibration is performed after each maintenance, then camera accuracy can be restored, but production efficiency decreases due to repeated calibration operations
Solution Approach 1:
The system performs automatic self-calibration by continuously capturing images of the reference line on the transparent protective plate and comparing the measured position against the known reference position. This self-service calibration occurs automatically during production without requiring manual intervention, restoring pixel accuracy without stopping the production line
Solution Approach 2:
The pixel calibration process is transformed from a discrete manual operation into a continuous automatic process. The system continuously captures reference line images and updates calibration parameters in real-time, ensuring pixel accuracy is maintained throughout production without interrupting the workflow
3Area of stationary object
If the camera viewing window is positioned to capture the coating material, then detection coverage is improved, but camera offset causes the viewing window to move out of the field of view
Solution Approach 1:
The transparent protective plate with its fixed reference line serves as a stable intermediary that defines a fixed viewing window position. The reference line's known position on the plate creates a stable reference frame that remains within the camera's field of view regardless of coating material movement or camera vibration
Solution Approach 2:
The reference line is pre-positioned and fixed on the transparent protective plate before production begins. This preliminary positioning establishes a known reference frame that the camera can continuously track, ensuring the viewing window remains within the field of view throughout operation
Data Source
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AI summary
A camera pixel calibration apparatus (100) and a winding device are provided. The camera pixel calibration apparatus (100) includes: a camera (10), where the camera (10) has a shooting lens (101); and a reference assembly (20), where the reference assembly (20) is disposed between the shooting lens (101) and a coating material (2), the reference assembly (20) includes a bracket (201) and a calibration plate (202), the bracket (201) is provided with a camera viewing window (201a), and the calibration plate (202) is disposed on a surface of the bracket (201) close to the shooting lens (101).