Infrared Camera Electrolyte Level Detection
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Solution Overview
Problem
Existing methods for monitoring electrolyte levels in batteries are either hazardous, require frequent maintenance, damage the battery container, or are costly and inefficient, particularly when trying to monitor multiple batteries simultaneously without mounting sensors on the container or cover.
Innovation Solution
A method using an infrared camera to capture temperature differences between the electrolyte and air, allowing for continuous monitoring of electrolyte levels in multiple batteries without emitting infrared beams, by processing images to locate temperature boundaries and triggering alarms if levels fall below a threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If internal resistance measurement is used to monitor electrolyte level, then electrolyte level can be determined, but operator safety is compromised due to electrical hazards
Solution Approach 1:
The patent replaces electrical measurement methods with optical measurement. Instead of using electrical current to measure internal resistance, the system uses an infrared camera to detect thermal patterns on the battery surface. This substitution eliminates electrical hazards while maintaining measurement capability through thermal imaging that detects temperature differences corresponding to electrolyte levels.
Solution Approach 2:
The patent introduces thermal radiation as an intermediary medium for measurement. The infrared camera detects thermal patterns on the battery surface, which serve as an intermediary indicator of electrolyte level without requiring direct electrical contact. This intermediary approach allows indirect measurement that avoids the harmful electrical effects.
2Measurement precision
If optical sensors are mounted on the battery container or cover, then electrolyte level can be monitored, but the container may be damaged
Solution Approach 1:
The patent extracts the measurement function from the battery container structure. Instead of mounting sensors on the container or cover, the system uses a remote infrared camera positioned away from the battery. This extraction eliminates the need for physical attachment that could damage the container while maintaining continuous monitoring capability through external thermal imaging.
Solution Approach 2:
The patent replaces mechanical sensor mounting with remote optical detection. Instead of physically attaching sensors to the container (which risks damage), the system uses an infrared camera to detect thermal patterns from a distance. This substitution maintains measurement precision while eliminating mechanical contact that could harm the container structure.
3Measurement precision
If multiple separate sensors are used to monitor each battery cell, then individual cell monitoring is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple measurement functions into a single infrared camera system. Instead of requiring separate sensors for each battery cell, the thermal imaging camera captures the entire battery or battery bank simultaneously, detecting temperature patterns that reveal electrolyte levels in multiple cells through a single unified measurement approach.
Solution Approach 2:
The patent makes the infrared camera a universal monitoring device that can detect electrolyte levels across multiple battery cells simultaneously. The single camera performs the function of multiple individual sensors by capturing thermal patterns from the entire battery structure, providing multi-functional capability that reduces overall system complexity.
4Measurement precision
If manual electrolyte level checking is performed, then accurate level determination is possible, but maintenance time and labor increase
Solution Approach 1:
The patent implements continuous automated monitoring using the infrared camera system, replacing intermittent manual checking. The camera continuously captures thermal patterns and the processing system continuously analyzes temperature distributions to detect electrolyte level changes in real-time, eliminating downtime between manual inspections while maintaining measurement accuracy through automated image processing.
Solution Approach 2:
The patent enables the battery monitoring system to serve itself through automated image processing algorithms. The system automatically captures thermal images, processes the temperature patterns, identifies electrolyte level conditions, and generates alerts without requiring operator intervention for each measurement, thereby eliminating manual labor while preserving accurate detection capability.
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
Enables efficient, safe, and cost-effective continuous monitoring of electrolyte levels in multiple batteries simultaneously, reducing maintenance needs and avoiding damage to the container, while using a single camera to monitor multiple cells at once.
Implementation Method 1
recording an image of the infrared radiations emitted by the wall and by the electrolyte through the wall of the battery
Implementation Method 2
recording an image of the infrared radiations emitted by the wall and by the electrolyte through the wall of the battery
Data Source
Figure 1
Figure 2
AI summary
A method for determining an electrolyte level in electrochemical cells of a battery or of a plurality of batteries, said method comprising the steps of : a) providing one battery or a plurality of batteries, each battery comprising a container having at least one wall; each battery consisting of one or several electrochemical cells; b) recording an image of the infrared radiations emitted by the wall and by the electrolyte through the wall of the battery or in case of a plurality of batteries recording an image of the infrared radiations emitted by the walls and by the electrolyte through the walls of the plurality of batteries; c) processing the image to locate in each electrochemical cell a boundary between two zones exhibiting a temperature difference thereby determining the electrolyte level in each electrochemical cell.