Prismatic Can Surface Inspection With Multi-Angle Edge Defect Imaging
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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, due to limitations in imaging technology.
Innovation Solution
An apparatus with multiple camera modules and lighting sections is employed to capture images from opposing directions, using coaxial and ambient lighting to illuminate surfaces at various angles, and a transport unit to position the can for comprehensive inspection, including inside and outside 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 is insufficient for detecting defects on three-dimensional curved surfaces and inside/outside surfaces
Solution Approach 1:
The inspection device is divided into multiple independent inspection units, each equipped with its own camera and lighting section. Each unit is responsible for inspecting specific surfaces (large surfaces or small surfaces) of the prismatic can, allowing for specialized high-precision inspection of each segment while maintaining overall system functionality.
Solution Approach 2:
The inspection system transitions from a single-point inspection to multi-angle three-dimensional inspection. By arranging inspection units at different positions and orientations around the prismatic can, the system captures images from multiple dimensions, enabling comprehensive defect detection on curved surfaces and inside/outside surfaces that cannot be inspected from a single viewpoint.
2Measurement precision
If multiple inspection units are used to inspect all surfaces, then the measurement precision improves, but the inspection time increases
Solution Approach 1:
The transport unit continuously moves the prismatic can through the inspection system, and multiple inspection units simultaneously capture images at different positions. This parallel inspection approach eliminates sequential inspection delays, maintaining continuous inspection action throughout the process while achieving comprehensive surface coverage.
Solution Approach 2:
The inspection process is segmented into parallel operations where different inspection units work simultaneously on different surfaces of the prismatic can. While one unit inspects large surfaces, another unit inspects small surfaces, enabling concurrent defect detection across all surfaces without requiring sequential inspection.
3Illumination intensity
If coaxial lighting is used, then the illumination intensity on the surface is high, but the ability to detect surface defects is reduced due to lack of shadow contrast
Solution Approach 1:
Different lighting sections provide different illumination qualities to different inspection needs. Coaxial lighting sections provide high-intensity uniform illumination for general surface viewing, while ambient lighting sections provide angled illumination that creates shadow contrast for defect detection. Each lighting type is optimized for its specific function, and both are used in combination.
Solution Approach 2:
The inspection system merges two types of lighting sections (coaxial and ambient) into a single integrated illumination system. The coaxial lighting section provides front illumination for overall surface visibility, while the ambient lighting section provides side illumination for defect highlighting through shadow effects, achieving both high illumination intensity and high defect detection precision simultaneously.
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 enables precise detection of defects on all surfaces of the prismatic can, improving inspection efficiency and accuracy by capturing images from multiple angles and orientations.
Implementation Method 1
a first camera module configured to capture the image of the large surface
Implementation Method 2
a first coaxial lighting section configured to irradiate light coaxially with the first camera module
Implementation Method 3
a first ambient lighting section configured to irradiate light at an angle of less than 45 degrees to the large surface
Data Source
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.