Prismatic Battery Can Inspection for Edge and Surface Defects
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Solution Overview
Problem
Existing inspection methods for battery prismatic cans struggle to accurately detect defects, particularly on three-dimensional curved surfaces and inside/outside surfaces, leading to potential defects in the final product.
Innovation Solution
An apparatus with paired inspectors and imaging modules that capture images from opposing directions, using coaxial and ambient lighting to illuminate surfaces at various angles, and adjustable mirrors to optimize image capture, allowing for precise detection of defects on both exterior and interior surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single inspection device is used, then the device complexity is low, but the measurement precision and defect detection accuracy are insufficient for three-dimensional curved surfaces and inside/outside surfaces
Solution Approach 1:
The inspection device is divided into multiple independent inspection modules, each equipped with its own imaging unit and lighting unit. Each module can independently inspect specific surfaces (inside or outside) of the can, allowing high-precision defect detection on three-dimensional curved surfaces without requiring a single complex device to handle all inspection tasks simultaneously.
Solution Approach 2:
The inspection system adds spatial dimensionality by positioning multiple inspection modules at different locations around the can. The can is rotated to present different surfaces to different modules, enabling comprehensive inspection of inside and outside surfaces from multiple angles and dimensions, thereby improving measurement precision on complex geometries.
2Measurement precision
If multiple inspection modules are used to inspect all surfaces, then the measurement precision improves, but the inspection time and productivity decrease due to sequential processing
Solution Approach 1:
The inspection system maintains continuous operation by rotating the can through multiple inspection modules in sequence. Each module inspects the can surface currently presented to it without interruption, and the can continuously rotates to present different surfaces to different modules, ensuring that the inspection process is continuous and uninterrupted, thereby maintaining high productivity while achieving comprehensive inspection.
Solution Approach 2:
The system employs dynamic rotation of the can during inspection, allowing different surfaces to be dynamically presented to different inspection modules. This dynamic approach enables multiple surfaces to be inspected simultaneously in a continuous flow, rather than requiring static, sequential inspection of each surface, thus improving both comprehensiveness and efficiency.
3Illumination intensity
If coaxial lighting is used, then the illumination intensity on the surface is high, but the ability to detect surface defects and edges is reduced due to lack of angular contrast
Solution Approach 1:
The lighting system employs different lighting configurations for different inspection needs: coaxial lighting units provide high illumination intensity for general surface brightness, while ambient lighting units positioned at angles provide contrast enhancement for defect detection. Each lighting unit is optimized for its specific function, allowing both high illumination and good defect contrast to be achieved simultaneously through local specialization.
Solution Approach 2:
The inspection module merges both coaxial lighting units and ambient lighting units into a single integrated system. The coaxial units provide bright illumination for overall surface visibility, while the ambient units provide angular lighting for defect contrast. By combining these complementary lighting approaches, the system achieves both high illumination intensity and effective defect detection capability.
4Area of stationary object
If the can is rotated significantly to present all surfaces, then the comprehensive inspection coverage improves, but the positioning precision and inspection consistency deteriorate due to posture changes
Solution Approach 1:
The inspection system divides the total inspection coverage into multiple segments, with each inspection module responsible for a specific surface or region of the can. Each module is positioned to inspect a particular area, and the can rotates to bring different segments into view of different modules. This segmentation allows comprehensive coverage while maintaining consistent positioning for each local inspection region.
Solution Approach 2:
The system pre-positions multiple inspection modules at specific locations around the can before inspection begins. Each module is positioned in advance to inspect a specific surface or region. The can then rotates to present the appropriate surface to the pre-positioned modules, eliminating the need for dynamic repositioning during inspection and maintaining consistent positioning accuracy throughout the process.
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 apparatus enhances the efficiency and accuracy of defect detection on battery prismatic cans by capturing comprehensive images from multiple angles, minimizing posture changes, and ensuring thorough inspection of all surfaces, including edges and interiors.
Implementation Method 1
a first coaxial lighting section configured to irradiate light coaxially with the first camera module
Implementation Method 2
a first ambient lighting section configured to irradiate light at an angle of less than 45 degrees to the large surface
Data Source
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AI summary
Disclosed is an apparatus for inspecting a prismatic can having a long side and a short side includes: a pair of large surface inspectors spaced apart by first spacing so that the can can enter a first inspecting position with its small surface having the short side first, and configured to capture images from opposing directions; and a pair of small surface inspectors spaced apart by second spacing so that the can can enter a second inspecting position with its large surface having the long side first, and configured to capture images from opposing directions. The apparatus for inspecting the appearance of a battery prismatic can according to the disclosure has an improved accuracy in detecting a defect on the edges as well as on multiple outer surfaces.