Automated Detection of Flexible Packaging Battery Electrode Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual visual checking for detecting missing electrode tabs in flexible packaging battery packs is inefficient and prone to errors, leading to potential accidents during the soldering process due to high workload and reduced detection accuracy.
Innovation Solution
A system utilizing a bus plate with slots and laser distance sensors to measure the distance between the sensors and protruding electrode tabs, with a robot arm and automatic linearly moving carrier plate for precise detection and removal of missing tabs, ensuring accurate and automatic detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual visual checking method is used to detect missing electrode tabs, then the detection process is simple to implement, but the detection efficiency is low and detection accuracy is reduced due to human fatigue
Solution Approach 1:
The patent replaces the manual visual checking method with an automated optical detection system. The system uses a light source to illuminate the electrode tab area and a camera to capture images, eliminating human fatigue and significantly improving both detection efficiency and accuracy. The automated system consistently detects the presence or absence of electrode tabs without the degradation in performance that occurs with prolonged manual inspection.
2Measurement precision
If automated detection system with camera is used, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The detection system is divided into distinct functional modules: a light source module for illumination, a camera module for image capture, and an image processing module for analysis. This segmentation allows each component to be optimized independently and simplifies the overall system design and maintenance while maintaining high detection accuracy.
Solution Approach 2:
The patent introduces an image processing module as an intermediary between the camera and the detection result. This intermediary processes the captured images to identify electrode tab presence, separating the complex tasks of image capture and analysis into distinct stages, thereby reducing the complexity of individual components while maintaining overall system accuracy.
3Reliability
If real-time detection is implemented during stacking process, then quality control is improved, but production time increases
Solution Approach 1:
The detection system is integrated into the stacking process to perform detection at the moment batteries are positioned, before subsequent assembly steps proceed. This preliminary detection ensures that batteries with missing electrode tabs are identified and removed early in the process, preventing downstream quality issues without adding significant production time, as the detection occurs concurrently with the stacking operation.
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 system achieves high detection accuracy and efficiency in identifying missing electrode tabs, preventing accidents and ensuring the quality of PACK flexible packaging batteries by automating the detection process during the stacking phase.
Implementation Method 1
the distance sensors include two laser distance sensors disposed side by side
Implementation Method 2
the distance sensors directly face protruding portions of the electrode tabs and are configured to measure a distance between the distance sensors and a protruding portion of the electrode tab nearest to the distance sensors
Data Source
AI summary
A system and method for detecting electrode tabs of a PACK flexible packaging battery relate to the field of PACK battery technologies. The system comprises a bus plate and a distance sensor, wherein through slots are disposed on the bus plate, and electrode tabs of a battery to be detected are inserted into the through slots during detection; and the distance sensor directly faces protruding portions of the electrode tabs of the battery to be detected after passing through the through slots, and is used for measuring the distance between the distance sensor and a protruding portion of an electrode tab nearest to the distance sensor.