Multi-Core Eddy Current Sensor for Battery Cell Crack Detection
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Solution Overview
Problem
Conventional eddy current sensors have low detection accuracy and high over-check rates when detecting cracks in lithium secondary battery cells, particularly due to their pencil-type design that results in inaccurate sensing positions and widened error ranges.
Innovation Solution
An eddy current sensor with multiple core units arranged to orient their central axes in the thickness direction of the battery cell, featuring a stepped case design and a 2x2 matrix configuration to enhance detection precision and reduce unchecked areas, along with a transfer unit and controller for automated non-destructive crack detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pencil-type eddy current sensor with a single core unit is used, then the device complexity is low, but the measurement precision and detection accuracy are insufficient
Solution Approach 1:
The sensor is divided into multiple core units (first core unit and second core unit) arranged in a specific configuration. Each core unit independently generates and detects eddy currents, allowing for multi-point sensing simultaneously. This segmentation improves measurement precision by reducing the error range and eliminating unchecked areas while maintaining manageable device complexity through modular architecture.
Solution Approach 2:
The core units are arranged in a three-dimensional configuration relative to the battery cell surface, with specific spacing and orientations. This spatial arrangement enables coverage of different areas and angles, improving detection accuracy by eliminating blind spots and reducing the over-check rate through optimized geometric distribution of sensing points.
2Measurement precision
If a pencil-type eddy current sensor is used for screening measurement, then the device structure is simple, but the sensing position accuracy is poor and the over-check rate is high
Solution Approach 1:
Multiple core units are distributed across the sensor body, each responsible for a specific sensing position. This segmentation enables simultaneous multi-point measurement, improving position accuracy by assigning dedicated sensing zones to each core unit while increasing inspection efficiency through parallel detection capability.
Solution Approach 2:
The sensor replaces mechanical scanning or screening methods with a fixed multi-core unit array that performs simultaneous electromagnetic sensing. This substitution eliminates the need for mechanical movement or screening procedures, improving sensing position accuracy through fixed geometric arrangement while enhancing productivity through parallel detection of multiple points.
3Reliability
If multiple core units are arranged in a matrix configuration, then the detection power and coverage are improved, but the device complexity increases
Solution Approach 1:
The sensor is segmented into multiple independent core units arranged in a matrix, with each unit contributing to overall detection reliability. This segmentation allows redundant sensing capability and cross-validation of measurements, improving reliability while maintaining modular construction that limits complexity growth.
Solution Approach 2:
Multiple core units are merged into a single integrated sensor assembly with common housing and control electronics. This merging approach improves reliability through combined detection capability while managing complexity by sharing structural and electronic components across all core units rather than treating them as completely separate devices.
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 solution enables high-resolution one-point sensing, reducing over-check rates and improving detection power by minimizing unchecked areas and eliminating abnormal magnetic fields, thus automating the detection of cracks in battery cells with increased precision.
Implementation Method 1
an eddy current sensor for inducing an eddy current and detecting the induced eddy current to detect a crack in a battery cell
Implementation Method 2
at least two core units in which a coil is wound around a magnetic member
Data Source
AI summary
An eddy current sensor for deriving an eddy current and sensing the derived eddy current in order to detect a crack in a battery cell, the eddy current sensor comprises: a core unit in which a coil is wound around a magnetic member; and a case for accommodating the core unit of which there are at least two, which are arranged so that the central axis of the coil is oriented in the thickness direction of the battery cell.