Camera Pixel Calibration Assembly for Vibration Offset Detection
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Solution Overview
Problem
Existing visual detection systems in battery manufacturing lack reliable anti-offset measures, leading to measurement errors and reduced production efficiency due to camera position or angle changes during continuous vibration or maintenance, resulting in defective cells being mistakenly removed and inconsistent calibration results.
Innovation Solution
A camera pixel calibration apparatus with a reference assembly, including a bracket and calibration plate, is used to prevent camera offset and calibrate pixel accuracy, ensuring the camera's viewing window remains within the field of view and providing a clear image for accurate detection, which includes a light source and a controller for blob analysis to calculate pixel accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual detection is used to monitor coating material parameters in real time, then detection speed and detection accuracy are improved, but camera offset due to vibration or cleaning leads to measurement errors and reduced reliability
Solution Approach 1:
A reference assembly including a calibration plate and bracket is introduced as an intermediary between the camera and the coating material. The calibration plate provides a stable reference target with known features that remains stationary relative to the camera, allowing the system to detect and compensate for camera offset caused by vibration or cleaning operations.
2Measurement precision
If manual calibration of camera pixel accuracy is performed after each maintenance, then pixel accuracy can be adjusted, but production efficiency is reduced and calibration consistency is poor
Solution Approach 1:
The system performs automatic self-calibration by capturing images of the calibration plate and using blob analysis algorithms to automatically calculate pixel accuracy. This eliminates the need for manual intervention after each maintenance operation, allowing calibration to occur quickly and consistently without stopping production, thereby maintaining both high pixel accuracy and production efficiency.
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 system continuously monitors the position of the calibration plate within the camera field of view and uses this feedback to detect any offset. When offset is detected, the system can trigger alarm signals or adjust the camera position to restore proper alignment, ensuring the viewing window remains within the field of view and detection coverage is maintained.
Data Source
AI summary
A camera pixel calibration apparatus and a winding device are provided. The camera pixel calibration apparatus includes: a camera, where the camera has a shooting lens; and a reference assembly, where the reference assembly is disposed between the shooting lens and a coating material. The reference assembly includes a bracket and a calibration plate, the bracket is provided with a camera viewing window, and the calibration plate is disposed on a surface of the bracket close to the shooting lens.