Cylindrical Battery Collector Plate Weld Checks by 4-Wire Resistance
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Solution Overview
Problem
Conventional methods for inspecting the welding state of a battery are destructive and inefficient, leading to production delays and potential battery damage.
Innovation Solution
A non-destructive method involving resistance measurement using probe units to determine the welding state of electrodes in a cylindrical battery, utilizing a 4-wire low-resistance direct current method to assess the quality of welds between current collector plates and other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a destructive inspection method for manually sampling welding regions is used, then welding quality can be determined, but production efficiency decreases and lots are held when issues arise
Solution Approach 1:
The patent replaces the mechanical destructive sampling method with an electrical measurement system. Resistance measurement using probe units contacts the current collector plates to detect welding quality electrically, eliminating the need for physical destruction of samples. This substitution enables non-destructive inspection that maintains production flow while determining weld quality.
Solution Approach 2:
The inspection system uses the battery components themselves (current collector plates and probe units) to perform the inspection. The resistance measurement leverages the existing electrical pathways through the welded components, allowing the product to inspect itself without requiring external destructive testing equipment or sample preparation.
2Reliability
If manual sampling of welding regions is performed, then welding state can be inspected, but inspection time increases and defects are detected late
Solution Approach 1:
The resistance measurement inspection is performed immediately after welding while the battery is still in the manufacturing line. The probe units contact the current collector plates right after the welding process, detecting defects before the battery proceeds to subsequent assembly steps. This preliminary detection prevents defective batteries from progressing further in production.
Solution Approach 2:
The inspection process is integrated into the continuous manufacturing flow. As batteries move along the production line, probe units continuously measure resistance values without interrupting the manufacturing process. This continuous inspection maintains production rhythm while providing real-time quality feedback.
3Measurement precision
If destructive inspection is used to determine welding quality, then accurate quality assessment is achieved, but battery damage occurs
Solution Approach 1:
The patent replaces mechanical destruction with electrical measurement. Instead of physically breaking or cutting samples to inspect welds, the system uses probe units to measure electrical resistance through the current collector plates. This electrical approach provides accurate welding quality assessment without causing any physical damage to the battery components.
Solution Approach 2:
The inspection method uses the inherent electrical properties of the welded components to assess quality. The resistance measurement leverages the existing electrical pathways through the current collector plates and welds, allowing the battery structure itself to provide the inspection data without requiring external destructive intervention.
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
Enables in-line total inspection of welding quality, improving production efficiency by identifying defects quickly and preventing defective batteries from progressing, thus enhancing overall battery quality.
Implementation Method 1
measuring resistance by contacting a first probe unit with an upper surface of a first current collector plate; measuring resistance by contacting a second probe unit with a lower surface of a second current collector plate
Data Source
AI summary
A method is provided to inspect weld states of a cylindrical battery. The cylindrical battery may include: a cylindrical jelly roll in which a first current collector, a first separator, a second current collector, and a second separator are sequentially stacked and wound, so as to extend in the vertical direction; a first collector plate which is coupled to the upper end of the jelly roll and to the lower surface of which the first current collector is firstly welded; and a second collector plate which is coupled to the lower end of the jelly roll and to the upper surface of which the second current collector is secondly welded. The method may include a first measurement step, a second measurement step, a first weld determination step, and a second weld determination step.