Battery Electrode Defect Detection With Alternating Illumination
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Solution Overview
Problem
The production of anodes and cathodes for batteries is complex and prone to defects, which can lead to inefficiencies and malfunctions in electrical vehicles if not identified during the production stage.
Innovation Solution
An apparatus comprising a controller, first and second contact image sensors, and synchronized illuminators with light beam splitters to detect defects on both faces of the anode or cathode by capturing interlaced images of grazing and deflected light beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for electrode defects, then the production process remains simple, but defect detection precision and reliability are insufficient
Solution Approach 1:
The inspection system is divided into multiple independent modules: first and second illuminators for different lighting angles, first and second contact image sensors for capturing images from different perspectives, and a controller for coordinating operations. Each module performs a specific function, allowing the complex inspection task to be broken down into manageable segments that can be optimized independently.
Solution Approach 2:
The patent combines multiple illumination sources (first and second illuminators with different lighting angles) and multiple image sensors into a single integrated inspection system. The controller merges the images captured by different sensors and processes them together to identify defects, achieving comprehensive defect detection that neither component could achieve alone.
2Reliability
If multiple inspection devices are deployed to detect defects on both faces of electrodes, then defect detection coverage improves, but the inspection system becomes more complex and time-consuming
Solution Approach 1:
The controller alternates between activating the first illuminator and second illuminator in periodic cycles. During each cycle, one illuminator is active while the other is inactive, allowing the system to capture images from different lighting conditions sequentially rather than simultaneously, reducing the total inspection time while maintaining comprehensive defect detection coverage.
Solution Approach 2:
The inspection system maintains continuous operation by seamlessly transitioning between the first and second illuminators. While one illuminator is active, the corresponding image sensor continuously captures images, ensuring that the inspection process never stops. This continuous action eliminates idle time between inspections and maintains high productivity.
3Measurement precision
If synchronized alternating illumination is used to capture images from different angles, then defect detection accuracy improves, but the control system complexity increases
Solution Approach 1:
The controller receives feedback signals from both image sensors indicating when images have been captured. Based on this feedback, the controller automatically switches between illuminators and coordinates the timing of image capture, ensuring that images are taken at the correct moments in the illumination cycle. This feedback mechanism simplifies the control logic by using sensor status to trigger the next control action.
Solution Approach 2:
The controller acts as an intermediary between the illuminators and image sensors, coordinating their operations without requiring direct complex interactions between them. It translates the simple on/off states of illuminators and the image capture events into synchronized alternating operation, managing the system's complexity centrally while keeping individual component interfaces simple.
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
Effectively detects defects on both faces of anodes and cathodes, ensuring production quality and reducing waste by identifying and correcting issues in real-time.
Implementation Method 1
a first light beam splitter; a first illuminator which is configured to send on said first light beam splitter first light beams, said first light beam splitter being configured to deflect at least part of said first light beams towards said first face of the anode or cathode
Implementation Method 2
a first contact image sensor configured to capture first and second images of at least part of said first face of the anode or cathode when illuminated by said at least part of said first light beams deflected and said second light beams
Data Source
AI summary
Apparatus for detecting defects in an anode or cathode for batteries. The anode or cathode includes a film of electrically conducting material coated on both of its opposite faces. The apparatus includes a controller and a device arranged along a transit path of the anode or cathode. The device includes a contact image sensor, a light beam splitter, a first illuminator and a second illuminator. The first illuminator directs first light beams onto the light beam splitter, which deflects the first light beams towards a first face of the anode or cathode. The second illuminator sends second beams of grazing light toward the first face. The controller drives the illuminators to emit the respective light beams in a synchronized and alternating manner. The contact image sensor captures images of the first face when illuminated and the controller detects the presence of defects based on the captured images.