Electrode Winding Deviation Detection with Dual-Camera Reference Alignment
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Solution Overview
Problem
During the winding process of electrode assemblies in battery manufacturing, positional deviations between electrode sheets and separators occur, affecting battery performance, and existing detection methods are inefficient due to limitations in camera positioning and image coordination.
Innovation Solution
A method and device using two cameras to capture images of the first and second electrode sheets, determining camera deviation by comparing distances to a specific position and then assessing electrode assembly deviation based on vertical distances from reference points in the images, ensuring accurate detection without additional images for camera alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two cameras are used to detect electrode assembly deviation, then detection capability is improved, but device complexity and cost increase
Solution Approach 1:
A laser projection device is introduced as an intermediary to project a laser line onto the electrode assembly. This laser line serves as a common reference that both cameras can capture, enabling coordinate transformation and deviation detection without requiring complex direct coordination between the two cameras. The laser line acts as a mediator that simplifies the relationship between the dual-camera system and the object being measured.
2Measurement precision
If additional images are captured to determine camera positioning, then camera alignment accuracy is improved, but detection time and process complexity increase
Solution Approach 1:
The laser projection device projects a laser line onto the electrode assembly before the cameras capture images. This preliminary action establishes a known reference pattern that simplifies subsequent image processing and camera coordinate transformation. By pre-establishing this reference, the system avoids the need for multiple additional calibration images, reducing detection time while maintaining positioning accuracy.
3Measurement precision
If traditional multi-image methods are used for deviation detection, then detection comprehensiveness is improved, but manufacturing efficiency decreases
Solution Approach 1:
The system merges the functions of laser projection and optical imaging into an integrated detection apparatus. The laser projection device and the two cameras work together as a unified system, capturing both electrode sheets and the laser reference line simultaneously. This merged approach achieves comprehensive deviation detection in a single operation, eliminating the need for multiple separate imaging steps and thereby improving manufacturing efficiency.
Data Source
AI summary
A deviation detection method includes obtaining first and second images of first and second electrode sheets, respectively, of an electrode assembly during winding using first and second cameras. The method further includes determining whether the first and/or second camera is deviated according to a distance from a reference point in the first and/or second image to a specific position, which is a position of a same object appearing in the first image and the second image. The method also includes determining whether the electrode assembly is deviated according to a vertical distance from the reference point in the first image to a boundary of the first electrode sheet and a vertical distance from the reference point in the second image to a boundary of the second electrode sheet if the first camera and the second camera are not deviated.