Electrode Plate Foreign Matter Detection Using Directional Lighting
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Solution Overview
Problem
Conventional quality inspection methods for rechargeable batteries are inadequate in detecting small foreign substances, particularly metal foreign materials and thin-film foreign materials, leading to potential defects and reduced productivity.
Innovation Solution
A device comprising a lighting unit that irradiates light brighter in one direction than others, a photographing unit, a controller, and a processor, which synthesizes images using photometric stereo and RGB color methods to enhance visibility of foreign substances, allowing accurate detection of both similar and dissimilar materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional quality inspection methods are used, then the inspection process is simple, but small foreign substances cannot be detected accurately
Solution Approach 1:
The inspection system segments the lighting function into multiple lighting units that can be independently controlled to provide illumination from different directions. This segmentation allows the system to capture images under various lighting conditions, enabling accurate detection of small foreign substances while maintaining a manageable system structure through modular design
Solution Approach 2:
The system transitions from single-direction lighting to multi-dimensional lighting by arranging lighting units in different spatial positions around the electrode plate. This dimensional expansion of the lighting approach enables the photographing unit to capture foreign substances from multiple angles, significantly improving detection accuracy without requiring a single overly complex imaging device
2Measurement precision
If multiple images are photographed from different directions, then foreign substances become more visible, but the inspection time increases
Solution Approach 1:
The controller implements periodic action by sequentially activating different lighting units in a predetermined order, with each lighting unit illuminating the electrode plate from its specific direction for a brief period. The photographing unit captures images during each lighting phase. This periodic, sequential operation enables multi-directional inspection while maintaining efficient timing that prevents excessive inspection duration
Solution Approach 2:
The system performs preliminary action by pre-arranging multiple lighting units in optimal positions around the electrode plate before inspection begins. The controller is pre-programmed with the sequencing logic for activating each lighting unit. This preliminary setup enables rapid execution of multi-directional imaging during actual inspection, reducing the time penalty that would otherwise result from ad-hoc positioning and control
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
Accurately distinguishes foreign substances on electrode plates, reducing defects and increasing productivity by enhancing the visibility of small foreign materials, thereby ensuring the quality of rechargeable batteries.
Implementation Method 1
a lighting unit capable of irradiating light toward an object that is brighter in one direction than other directions
Implementation Method 2
a diffusion member made of a transparent material, installed in the penetrated portion of the body member, and the diffusion member capable of diffusing light irradiated by the light-emitting device
Implementation Method 3
a photographing unit spaced from the lighting unit and capable of photographing the object
Data Source
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AI summary
A device (100) for detecting foreign substances (M) comprising: a lighting unit (120) for irradiating light toward an object (E) that is brighter in one direction than other directions or uniformly irradiating light toward the object (E); a photographing unit (130) spaced from the lighting unit (120) and capable of photographing the object (E); a controller (140) capable of: allowing the photographing unit (130) to the photograph the object (E) each time the lighting unit irradiates light toward the object that is brighter in one direction than other directions, and controlling the lighting unit (120) and the photographing unit (130) to allow the photographing unit (130) to photograph the object (E) if the lighting unit (120) uniformly irradiates light toward the object (E); and a processor (150) capable of synthesizing images photographed by the photographing unit (130) and determining whether the object (E) has foreign substances (M) from the synthesized image.