Electrode Winding Gap Detection Without Camera Calibration
Find Innovative SolutionsGenerate Solutions
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, leading to inadequate detection accuracy and efficiency.
Innovation Solution
A method and system that calculates electrode plate winding gaps using width data obtained from previous cutting processes and sampled images post-winding, without the need for pre-calibration of cameras, to determine gaps between electrode plates and separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional machine vision detection solutions are used to detect gaps between wound electrode plates, then detection can be performed, but detection accuracy and detection efficiency are insufficient
Solution Approach 1:
The patent replaces traditional mechanical camera calibration systems with a calculation-based approach. Instead of using calibrated cameras to directly measure gap distances, the system uses image processing to detect edge positions and calculates actual gap distances by combining these positions with pre-stored width data from the cutting process, substituting complex optical calibration with simpler computational geometry.
Solution Approach 2:
The patent performs preliminary action by storing the widths of the anode plate, cathode plate, and separator during the cutting process before winding occurs. This pre-acquired data is then used during the gap detection phase to calculate actual gap distances, eliminating the need for complex real-time calibration and improving both detection accuracy and efficiency.
2Measurement precision
If camera calibration is performed in advance to obtain accurate gap measurements, then measurement precision improves, but detection steps become more complex and time-consuming
Solution Approach 1:
The patent substitutes the complex mechanical calibration process with a computational approach. The system stores width data from the cutting process and uses it together with edge detection results to calculate gap distances through simple mathematical operations, replacing the need for intricate camera calibration procedures.
Solution Approach 2:
The patent performs the calibration-like function in advance by storing the widths of electrode plates and separator during cutting. This preliminary data acquisition eliminates the need for complex real-time calibration steps, simplifying the detection process while maintaining measurement accuracy.
3Measurement precision
If multiple cameras are used to capture images before and after winding for accurate gap calculation, then detection accuracy improves, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential information needed for gap calculation - the edge positions of electrode plates and separator in the wound state. By combining this extracted information with pre-stored width data from cutting, the system calculates gap distances without requiring multiple cameras or images taken at different stages, simplifying the device configuration.
Solution Approach 2:
The patent makes the single camera system multi-functional by using it to capture images after winding and combining this with pre-stored cutting data. This approach replaces the need for multiple specialized cameras (before-winding cameras and after-winding cameras), as the system universally handles gap detection through computational methods.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present application discloses a method, apparatus, and system for detecting an electrode plate winding gap. 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. The gap between the electrode plates is calculated in conjunction with width data obtained in a previous process, without calibrating cameras for acquiring images in advance, which simplifies detection steps and improves the accuracy of detection.