Infrared Unit Cell Edge Inspection for Electrode Alignment
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Solution Overview
Problem
Existing methods struggle to accurately measure the position of the negative electrode within a unit cell, leading to significant deviations in the full length and full width between unit cells, which can result in placement failures.
Innovation Solution
A unit cell inspecting device using long-wave infrared rays to capture images of the electrode edges, particularly the negative electrode, and measure its position, while inspecting for deformations, is employed in conjunction with electrode assembly manufacturing equipment to align unit cells based on the negative electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If visual inspection is performed by工作人员 manually, then flexibility in handling various defects is maintained, but inspection speed is slow and labor costs are high
Solution Approach 1:
The inspection system is divided into multiple independent inspection units, each equipped with its own light source and imaging device. Each unit independently inspects a specific region of the electrode assembly, allowing parallel processing of different areas simultaneously, thereby increasing overall inspection speed without requiring a single complex centralized system.
Solution Approach 2:
The inspection system uses standardized inspection units that can be configured to detect various types of defects including welding defects, foreign objects, and structural abnormalities. The same basic unit structure serves multiple inspection purposes by adjusting imaging parameters and light source configurations, reducing overall system complexity while maintaining versatility.
2Productivity
If multiple inspection units are arranged in parallel, then inspection speed increases, but device complexity and space requirements increase
Solution Approach 1:
Multiple inspection units are arranged in a nested configuration where imaging devices and light sources are positioned within or adjacent to each other in a compact manner. The units share common structural support and can be vertically or horizontally stacked, reducing the overall footprint while maintaining parallel inspection capabilities.
Solution Approach 2:
The inspection units are arranged in three-dimensional space rather than simply expanding in one direction. By utilizing vertical stacking and angular positioning, the system achieves parallel inspection coverage without proportionally increasing the horizontal footprint, effectively using spatial dimensions to pack multiple units efficiently.
3Reliability
If transparent protective plates are used to protect electrodes, then electrode protection is improved, but light transmission is reduced affecting image quality
Solution Approach 1:
The protective plate is made from composite or specially formulated transparent materials that balance mechanical protection properties with optical transmission characteristics. The material composition is optimized to provide sufficient structural strength for electrode protection while maintaining high light transmission in the wavelength range used by the imaging devices.
Solution Approach 2:
The optical properties of the protective plate are optimized by adjusting parameters such as thickness, material composition, and surface treatment. By carefully controlling these parameters, the plate provides adequate mechanical protection while minimizing light absorption and scattering, thereby maintaining image quality for defect detection.
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
This approach allows for precise measurement and alignment of unit cells, reducing deviations and preventing placement failures, thereby enhancing the manufacturing process efficiency and quality of electrode assemblies.
Implementation Method 1
a light source and an imaging device that images the electrode assembly using the light source
Data Source
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Figure 5
AI summary
A unit cell inspecting device according to the present invention includes an inspection unit which captures an image of an edge of a unit cell by using long-wave infrared rays and measures a position of an edge of an electrode provided in the unit cell. The inspection unit includes: a main heating part configured to heat the edge of the unit cell, thereby raising a temperature of the edge of the electrode provided in the unit cell; and an image capturing part configured to capture the image of the edge of the unit cell by using the long-wave infrared rays, thereby acquiring a thermal image of the edge of the electrode provided in the unit cell; and an inspection part configured to measure the edge of the electrode in the thermal image captured by the image capturing part, thereby measuring the position of the electrode by using the measured edge of the electrode.