Electrode Stacking Inspection Using Corner Imaging and Light Feedback
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Solution Overview
Problem
The existing stacking processes for lithium secondary batteries face challenges in ensuring accurate alignment of cathode and anode electrodes, leading to defects such as twisting and reduced yield, particularly during the folding and lamination of unit cells, which affects the battery's performance, safety, and quality.
Innovation Solution
A stacking inspection apparatus equipped with camera units and light irradiation units that photograph and irradiate four corner points of the electrodes or unit cells to determine alignment defects and measure thickness, using sensors to recognize light signals and correct alignment in real time, thereby minimizing manual measurement errors and improving product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and alignment adjustment is used during stacking process, then flexibility and ease of operation are maintained, but measurement precision and manufacturing precision deteriorate due to human error and time consumption
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical inspection system. Camera units capture images of electrode plates, and a control unit automatically processes these images to detect alignment defects, substituting human operators and manual measurement tools with an automated vision-based system that provides higher precision without requiring complex manual adjustment mechanisms
Solution Approach 2:
The patent uses camera units to create optical copies (images) of the electrode plates and their corner points. By capturing and analyzing these visual copies rather than performing direct physical measurements, the system achieves high measurement precision through image processing algorithms while maintaining a relatively simple apparatus structure
2Productivity
If the number of stacked unit cells is increased to improve productivity, then output increases, but alignment precision deteriorates due to cumulative stacking errors
Solution Approach 1:
The patent implements a feedback mechanism where the inspection apparatus continuously monitors alignment of stacked unit cells and provides real-time detection of deviation amounts. This feedback information enables corrective actions to be taken during the stacking process, preventing cumulative errors from accumulating even as productivity increases through faster stacking rates
Solution Approach 2:
The inspection apparatus performs preliminary detection of alignment status before significant deviations accumulate. By detecting corner point positions and calculating alignment deviations early in the stacking process, the system can identify and correct issues before they propagate through multiple stacked units, maintaining precision across large numbers of stacked cells
3Manufacturing precision
If real-time inspection is implemented during stacking process, then manufacturing precision is improved, but productivity deteriorates due to additional inspection time
Solution Approach 1:
The patent enables continuous inspection during the stacking process rather than requiring separate inspection stages. The camera units and control unit operate concurrently with stacking operations, continuously capturing images and processing alignment data without interrupting the stacking flow, thereby maintaining both high precision and productivity
Solution Approach 2:
The patent replaces time-consuming manual measurement and adjustment operations with automated optical inspection and image processing. The rapid capture and digital analysis of corner point positions enable real-time alignment verification without the mechanical delays associated with manual measurement tools, maintaining stacking throughput while improving precision
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 apparatus enables real-time detection and correction of alignment defects and thickness deviations, enhancing the quality and yield of lithium secondary batteries by automating the alignment process and reducing errors associated with manual measurements.
Implementation Method 1
light irradiation units that irradiate a light signal to four corner points of the first electrode plate and the second electrode plate as inspection objects
Data Source
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AI summary
The present disclosure provides a stacking inspection apparatus including: camera units that generate an aligned image by photographing four corner points of the outer periphery of the electrode plates or the unit cells at an upper part in a stacking direction of the electrode plates or the unit cells; and light irradiation units that irradiate light signals to four corner of the inspection object, and sensors that recognize the light signal irradiated from the light irradiation units and determine whether or not alignment of the first electrode plate and the second electrode plate is defective.