Electrode Plate Winding Gap Detection Using Width Data and Edge Images
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Solution Overview
Problem
Existing machine vision detection solutions for electrode plate winding gaps in battery cell production are limited by structural design, cost, and application scenarios, resulting in suboptimal detection accuracy and efficiency.
Innovation Solution
A method and system that calculates electrode plate winding gaps using width data from the previous cutting process and sampled images after winding, without the need for camera calibration, simplifying detection steps and improving accuracy by directly determining gaps between electrode plates and separators based on acquired image data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera calibration is performed in advance for machine vision detection, then detection accuracy can be maintained, but detection steps become complex and time-consuming
Solution Approach 1:
The patent performs camera calibration in advance to obtain calibration parameters, then stores these parameters for later use in gap detection. This preliminary calibration action eliminates the need for repeated calibration during actual detection, thereby simplifying the detection process while maintaining accuracy.
Solution Approach 2:
The patent creates a calibrated coordinate system model that maps camera image coordinates to real-world physical dimensions. This copied coordinate relationship allows direct calculation of gap distances from image measurements without requiring physical measurement tools during detection.
2Loss of information
If multiple cameras are used to capture images before and after winding, then comprehensive detection data can be obtained, but system complexity and cost increase
Solution Approach 1:
The patent extracts only the essential information needed for gap detection - specifically, the positions of electrode plate edges in the image. By focusing on extracting only this critical data rather than analyzing complete pre- and post-winding images, the system achieves accurate gap measurement with simpler imaging requirements.
Solution Approach 2:
The patent introduces a calibration parameter set as an intermediary that bridges the relationship between image coordinates and physical dimensions. This intermediary allows a single camera to provide sufficient detection data by enabling accurate conversion from pixel measurements to real-world gap distances through the calibrated coordinate system.
3Productivity
If fixed detection parameters are used for specific electrode plate sizes, then detection speed is improved, but adaptability to different plate sizes decreases
Solution Approach 1:
The patent implements dynamic detection parameters that automatically adjust based on the detected electrode plate dimensions. The system calculates detection thresholds and parameters in real-time according to the actual plate size, enabling both fast detection (through automated parameter selection) and high adaptability (through size-specific parameter optimization).
Data Source
AI summary
Method, apparatus, and system for detecting an electrode plate winding gap are provided. The method for detecting the electrode plate winding gap includes: acquiring a first width of an anode region covering a surface of the first electrode plate, a second width of a cathode region, and a third width of a protective region determined after electrode plates are cut; receiving sampled images of edges of two sides of a separator, the first electrode plate, and a second electrode plate after winding; determining a gap between the first electrode plate and the second electrode plate from the sampled images; and calculating a gap between the anode region and the cathode region as well as a gap between the anode region and the protective region according to the first width, the second width, the third width, and the gap between the first electrode plate and the second electrode plate.