Electrode Stack Edge Measurement for Inline Deposition Accuracy
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Solution Overview
Problem
Current methods for determining the deposition accuracy of electrode sheets in a lithium-ion battery stack are costly, time-consuming, and not inline-capable, with limitations in measuring the precise positioning of electrode sheets using X-rays or computer tomography, and existing optical detection methods are not effective for real-time monitoring.
Innovation Solution
A method utilizing a camera and light source to capture and evaluate the positions of boundary edges of electrode sheets in a stack, employing coherent or collimated light and artificial intelligence, specifically convolutional neural networks, to determine the deposition accuracy of anode, cathode, and separator sheets, enabling real-time, inline-capable monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If computer tomography (CT) is used to determine deposition accuracy, then measurement precision is improved, but measurement time increases significantly and inline capability is lost
Solution Approach 1:
The patent extracts only the essential measurement information (boundary edge positions of electrode sheets) from the complex CT measurement process. By using simple optical projection instead of full 3D tomography, it obtains the necessary deposition accuracy data without the lengthy measurement time required by CT, achieving both precision and speed.
Solution Approach 2:
The patent replaces the complex mechanical scanning system of CT with a simple optical projection system using light sources and cameras. This substitution maintains measurement precision for boundary edge detection while dramatically reducing measurement time and enabling inline capability.
2Measurement precision
If X-ray methods are used to measure electrode sheet positions, then measurement capability is improved, but investment and operating costs increase
Solution Approach 1:
The patent replaces expensive X-ray equipment with inexpensive optical components (light sources and cameras). This substitution achieves the same measurement capability for electrode sheet positions at a fraction of the cost, eliminating the need for high investment and operating expenses associated with X-ray systems.
Solution Approach 2:
The patent substitutes the complex X-ray measurement system with a simple optical system. This replacement maintains the ability to measure electrode sheet positions accurately while dramatically reducing device complexity, investment costs, and operating expenses.
3Measurement precision
If X-ray methods are used for measurement, then measurement capability is improved, but radiation protection requirements increase
Solution Approach 1:
The patent converts the harmful X-ray radiation into harmless visible light. By using optical projection instead of X-rays, it achieves the same measurement capability without radiation exposure, eliminating the need for radiation protection measures while maintaining measurement precision.
Solution Approach 2:
The patent replaces the harmful X-ray measurement system with a harmless optical system. This substitution eliminates radiation exposure and associated protection requirements while maintaining the ability to measure deposition accuracy effectively.
4Productivity
If optical detection methods are used, then measurement speed is improved, but measurement precision for boundary edges deteriorates
Solution Approach 1:
The patent applies local quality by using different optical illumination strategies for different measurement needs. It employs coherent or collimated light specifically for boundary edge detection to maintain precision, while using standard optical methods for other areas, thus achieving both speed and precision where needed.
Solution Approach 2:
The patent changes the optical parameters (using coherent or collimated light) to improve boundary edge detection precision while maintaining fast measurement speed. This parameter adjustment allows the optical system to achieve CT-level precision without the time penalty.
5Productivity
If recording during stacking process is done, then real-time monitoring is improved, but data volume increases and cycle time reduction is limited
Solution Approach 1:
The patent extracts only the critical information (boundary edge positions) during the stacking process, rather than recording all raw data. This extraction approach enables real-time monitoring for quality control while keeping data volume manageable and not significantly increasing cycle time.
Solution Approach 2:
The patent performs preliminary measurement of boundary edge positions during the stacking process itself, before final assembly. This preliminary action enables real-time detection of deposition accuracy issues while minimizing additional data processing requirements and cycle time extension.
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
This approach allows for accurate, efficient, and cost-effective determination of electrode sheet positions, improving the electrochemical performance and safety of lithium-ion battery cells by ensuring precise alignment, reducing cycle time, and minimizing radiation exposure.
Implementation Method 1
illuminating the stack with the light source so that light beams pass through at least a region of the stack or are reflected from the region
Implementation Method 2
the light beams are being detected by the camera; capturing an image (or multiple images) of at least the region of the stack with the camera
Data Source
AI summary
A method for determining a deposition accuracy of a plurality of electrode sheets, which each comprise at least one anode sheet, one cathode sheet and one separator sheet. The electrode sheets extend in mutually parallel planes and are arranged stacked on top of one another and form a stack. The deposition accuracy describes a respective position of at least boundary edges of one of the electrode sheets in the stack. The method is performed with a measuring device comprising at least a camera and a light source. A measuring device for carrying out the method is also provided.