Electrode Plate Inspection Using Regional Lightness Correction
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Solution Overview
Problem
Existing electrode plate inspection methods fail to accurately detect depressions on the coating material due to variations in lightness among normal portions, leading to incorrect detection of defects.
Innovation Solution
An electrode plate inspection method and apparatus that uses oblique linear light to acquire specular reflection, divides the reflection into regions, calculates a correction value to uniform lightness, and detects dark portions below a threshold as depressions, ensuring accurate identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional illumination is used to detect depressions, then the inspection process is simple, but lightness variations in normal portions cause incorrect detection
Solution Approach 1:
The width direction of the coating material is divided into multiple regions, and lightness values are segmented and processed for each region. This allows local lightness variations to be corrected independently, improving depression detection accuracy without requiring a completely complex inspection system.
Solution Approach 2:
The patent changes the illumination parameter by using oblique linear light instead of conventional illumination, and modifies the lightness parameter through regional correction values. This transforms the raw lightness data into corrected lightness values that eliminate positional variations, enabling accurate depression detection.
2Manufacturing precision
If pressing of the coating material is performed, then the coating density is improved, but lightness variations among positions increase making depression detection difficult
Solution Approach 1:
The patent applies a correction parameter (correction value) to the lightness measurements based on the regional division. This parameter transformation compensates for the lightness variations caused by pressing, allowing accurate depression detection even when the coating has been densely pressed.
3Productivity
If a fixed lightness threshold is used for depression detection, then the detection process is simple, but depressions cannot be correctly detected due to lightness variations in normal portions
Solution Approach 1:
Instead of using a single fixed threshold for the entire coating material, the patent applies different correction values to different regions in the width direction. This local quality approach allows each region to have its own lightness characteristics accounted for, improving detection accuracy while maintaining relatively simple processing.
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
The method effectively distinguishes normal and depressed regions by enhancing lightness differences, allowing for correct detection of depressions despite variations in lightness across the electrode plate.
Implementation Method 1
obliquely applying linear light extending in a width direction of the electrode plate onto a surface of the coating material, and moving the electrode plate relative to the light in a longitudinal direction orthogonal to the width direction, acquiring specular reflection of the light by the coating material
Data Source
AI summary
Inspection of detecting a depression includes obliquely applying linear light extending in a width direction of an electrode plate onto a surface of a coating material, and moving the electrode plate in a longitudinal direction, acquiring specular reflection of the light by the coating material, dividing the acquired specular reflection in the width direction, and obtaining a representative value of lightnesses at multiple positions in the longitudinal direction for each of a plurality of regions in the width direction, obtaining a correction value with which the representative values of lightnesses are uniform among the regions in the width direction, for each of the regions, adding the correction value to the lightnesses of the specular reflection in each of the regions, and detecting a dark portion with a lightness lower than a predetermined threshold, in a lightness distribution of the specular reflection after addition of the correction values.