Separator Plate Assembly Alignment Using Optical Emboss Detection
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Solution Overview
Problem
Existing separator plate assemblies for electrochemical systems face inaccuracies and assembly errors due to misalignment of embossed and stamped structures, which are not detectable or correctable with sufficient accuracy using existing measuring structures, and are often time-consuming and costly to implement.
Innovation Solution
A separator plate assembly comprising a first metal sheet with a through-hole and an embossed structure, and a second metal sheet with an embossed structure aligned by the projection of the through-hole, allowing for contactless detection of alignment deviations and correction before joining, using imaging and image recognition methods to ensure accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing measuring structures are used to detect alignment deviations, then measurement capability is provided, but measurement precision and detection accuracy are insufficient to detect assembly errors with sufficient accuracy
Solution Approach 1:
The patent uses optical imaging to create a digital copy of the measuring structure for analysis. Instead of complex physical measurement devices, an optical sensor captures an image of the measuring structure, and image recognition software processes this copy to detect alignment deviations with high precision.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with an optical-mechanical system. Alignment detection is achieved through optical imaging and image processing rather than mechanical contact measurement, simplifying the device while improving measurement precision.
2Manufacturing precision
If traditional assembly methods are used without precise alignment detection, then production speed is maintained, but assembly accuracy deteriorates due to undetected misalignment
Solution Approach 1:
The patent performs alignment detection before the joining process. By detecting misalignment of embossed and stamped structures prior to assembly, the system allows for correction of positioning errors before final joining, ensuring high assembly accuracy without requiring rework later.
Solution Approach 2:
The patent implements a feedback mechanism where optical sensors detect alignment status and provide information for correction. The image recognition system analyzes the measuring structure and provides feedback on positioning accuracy, enabling real-time adjustment before joining to maintain both precision and productivity.
3Measurement precision
If complex measuring structures are implemented to improve detection accuracy, then measurement capability is enhanced, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent uses inexpensive optical imaging to create a digital representation of the measuring structure. Instead of expensive specialized measurement instruments, standard optical sensors and image processing software are used to achieve high measurement precision, significantly reducing manufacturing costs.
Solution Approach 2:
The patent employs cost-effective optical components and software-based measurement rather than expensive durable measurement equipment. The optical imaging system and image recognition algorithms provide accurate measurement at a fraction of the cost of traditional precision mechanical measurement 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 easy and cost-effective detection and correction of assembly inaccuracies, improving the accuracy and quality of the separator plate assembly by aligning embossed and stamped structures before joining, thus enhancing the production process.
Implementation Method 1
an optical sensor and that, using a pattern or image recognition software, are used to establish a coordinate system
Implementation Method 2
transmitted light processes, in which the light source and the image detector are arranged on different sides of the plate
Data Source
AI summary
A separator plate assembly for an electrochemical system, comprising a first metal sheet and a second metal sheet, which are in contact with one another at least in areas along the flat sides thereof facing one another, the first metal sheet including a first through-hole, or a group of first through-holes, and a first embossed structure surrounding the first through-hole, or the group of first through-holes, of the first metal sheet, and the second metal sheet including a first embossed structure, which is arranged at least in sections in an area of the second metal sheet that is defined by a perpendicular projection of the first through-hole, or of the group of first through-holes, of the first metal sheet onto the second metal sheet.