Optical Welding Defect Inspection Using IR, Plasma, and Spectral Sensing
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Solution Overview
Problem
Existing welding defect inspection methods for secondary batteries are time-consuming and often destructive, limiting their application to sampling.
Innovation Solution
An optical device comprising an infrared detection unit, visible light detection unit, and spectroscopic unit to detect heat, plasma, and wavelength-specific luminosity during welding, combined with a machine learning model trained on reference optical measurement data to determine welding defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional welding defect inspection methods are used, then inspection accuracy can be maintained, but inspection time increases and the process becomes destructive
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with an optical detection system that uses infrared sensors, visible light sensors, and spectroscopic units to detect welding defects. This substitution enables non-contact, real-time detection during the welding process itself, eliminating the need for post-welding mechanical inspection and thereby reducing inspection time while maintaining accuracy
Solution Approach 2:
The system performs defect detection during the welding process rather than after completion. By detecting thermal radiation, plasma characteristics, and spectral signatures in real-time, the system identifies defects as they form, allowing for immediate feedback without requiring separate post-inspection steps
2Reliability
If traditional inspection methods are used, then defect detection capability is sufficient, but the inspection process destroys the target object
Solution Approach 1:
The patent replaces destructive mechanical or chemical inspection methods with non-contact optical sensing. The system uses infrared detection units to measure thermal radiation, visible light detection units to capture plasma emission, and spectroscopic units to analyze wavelength-specific luminosity, all without physically contacting or damaging the weldment
Solution Approach 2:
The system introduces optical fields as intermediaries to detect welding defects. Instead of directly examining the weldment structure, the system detects the electromagnetic radiation (infrared, visible light, spectral signatures) emitted during welding, which serves as an indirect but non-destructive indicator of defect presence
3Measurement precision
If multiple detection units are added to improve detection accuracy, then measurement precision increases, but device complexity increases
Solution Approach 1:
The patent divides the detection system into three specialized units: infrared detection units for thermal radiation, visible light detection units for plasma emission, and spectroscopic units for wavelength analysis. Each unit is optimized for detecting specific physical phenomena, allowing the system to achieve high measurement precision through targeted detection rather than using a single complex device
Solution Approach 2:
The optical detection device is designed to perform multiple detection functions simultaneously using different physical principles. The same device structure accommodates infrared sensors, visible light sensors, and spectroscopic units that can operate concurrently during welding, providing comprehensive defect detection through multi-parameter measurement without requiring separate inspection equipment
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 rapid, non-destructive welding defect inspection without destroying the inspection target, improving the performance of the trained machine learning model by clearly representing welding characteristics in the image.
Implementation Method 1
an infrared detection unit that detects heat generated at a weldment during welding
Implementation Method 2
a visible light detection unit that detects plasma generated at the weldment
Implementation Method 3
a spectroscopic unit that detects wavelength-specific luminosity at the weldment
Data Source
AI summary
An optical device may include an infrared detection unit that detects heat generated at a weldment during welding, a visible light detection unit that detects plasma generated at the weldment and a spectroscopic unit that detects wavelength-specific luminosity at the weldment, wherein the optical device determines an occurrence of welding defects at the weldment based on the detected heat, the detected plasma, and/or the detected wavelength-specific luminosity of the weldment.