Battery Electrode Defect Detection With Synchronized Dual Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for detecting defects in the production of battery anodes and cathodes are inefficient, leading to potential malfunctions in electrical vehicles and production inefficiencies.
Innovation Solution
An apparatus comprising contact image sensors and synchronized illuminators with light beam splitters is used to capture and analyze images of both faces of the anodes and cathodes, detecting defects such as cracks, wrinkles, and misalignments through synchronized illumination and image capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing defect detection methods are used in battery electrode production, then production continues at current speed, but defect detection effectiveness is insufficient leading to potential malfunctions and waste
Solution Approach 1:
The inspection system is divided into multiple independent inspection units, each equipped with its own illuminators and contact image sensors. Each unit can independently inspect different sections of the electrode, allowing parallel processing that maintains high production speed while ensuring thorough defect detection across the entire electrode surface
Solution Approach 2:
The system performs preliminary defect detection during the electrode production process itself, rather than as a separate post-production step. By integrating inspection units along the production line, defects are identified in real-time, enabling immediate corrective actions without stopping production, thus maintaining productivity while improving reliability
2Measurement precision
If comprehensive defect inspection is performed on both faces of electrodes, then defect detection accuracy improves, but inspection system complexity increases
Solution Approach 1:
The inspection system is divided into multiple independent inspection units, each equipped with its own illuminators and contact image sensors. Each unit can independently inspect different sections of the electrode, allowing parallel processing that maintains high production speed while ensuring thorough defect detection across the entire electrode surface
Solution Approach 2:
The system inspects both faces of the electrode by arranging inspection units to access different surfaces. By adding the dimensional aspect of dual-face inspection, the system achieves comprehensive defect detection without requiring complex manipulation of the electrode, as each inspection unit is independently configured for its specific inspection angle and surface
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 identifies defects in anodes and cathodes, ensuring higher production quality and reducing waste by improving defect detection during the manufacturing process.
Implementation Method 1
synchronized illuminators with light beam splitters is used to capture and analyze images of both faces
Implementation Method 2
capture and analyze images of both faces of the anodes and cathodes, detecting defects through synchronized illumination and image capture
Data Source
Figure 1
Figure 2
AI summary
Apparatus (100) for detecting defects in an anode or cathode for batteries, the anode or cathode comprising a film (1) of electrically conducting material coated at least partially on both of its opposite faces by a coating layer (3). The apparatus comprises: - a controller (10); - a device which is arranged along a transit path of the anode or cathode to be controlled and comprises: - a contact image sensor (12); - a light beam splitter (14); - a first illuminator (16) sending on the light beam splitter first light beams (A), the light beam splitter deflecting the first light beams towards a first face of the anode or cathode; - a second illuminator (18) sending second beams (B) of substantially grazing light toward the first face. The controller drives the illuminators to emit the respective light beams in a synchronized and alternating manner with each other. 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.