Separator Roll Defect Inspection via Electromagnetic Scanning
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Solution Overview
Problem
Existing defect inspection devices for separator rolls in lithium-ion batteries face challenges in accurately detecting defects, particularly when the defect is moving with the sheet or when the inspection area is larger than the detector, leading to false negatives and incomplete inspections.
Innovation Solution
A defect inspection device that includes a holding mechanism to stabilize the separator roll, a radiation source to emit electromagnetic waves, and a sensor to detect these waves before and after the roll is moved relative to the source, allowing for comprehensive and accurate defect detection across a wide area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sheet is conveyed during inspection, then the inspection process is continuous, but the defect moves together with the sheet making accurate determination difficult
Solution Approach 1:
The patent creates a stationary copy or image of the moving sheet at the moment of defect detection. By capturing the defect position on the conveyed sheet and referencing it against a fixed detection point, the system can accurately determine defect locations even though the sheet is in motion. This copying approach allows continuous inspection while maintaining measurement precision.
2Area of stationary object
If the detector area is smaller than the target object area, then the device is more compact, but the inspection cannot cover sufficient region leading to false negatives
Solution Approach 1:
The patent employs dynamic scanning where the detector moves relative to the separator roll or the roll moves through the detection zone. This dynamic approach allows a smaller detector to inspect a larger area over time by systematically scanning different regions. The inspection completeness is maintained through multiple passes or continuous movement that ensures full coverage of the separator roll surface.
Solution Approach 2:
The inspection area is divided into multiple smaller detection zones that are scanned sequentially. By segmenting the large inspection area into manageable sections and inspecting each section systematically, the patent enables a smaller detector to cover the entire separator roll surface without missing defects, thus maintaining inspection reliability while using a compact detector.
3Measurement precision
If electromagnetic wave inspection is performed on separator rolls, then defects can be detected, but the separator roll must be moved relative to the source for comprehensive scanning
Solution Approach 1:
The patent combines the electromagnetic wave generation, detection, and rolling motion control into an integrated inspection system. By merging these functions, the system achieves comprehensive defect detection without requiring complex separate mechanisms for each function. The relative movement is achieved through coordinated operation of the rolling mechanism and detection system, reducing overall device complexity while maintaining inspection effectiveness.
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 accurate and thorough defect inspection of separator rolls by ensuring that the entire area is scanned without false negatives, improving the reliability of identifying defects within the separator.
Implementation Method 1
a radiation source section configured to emit an electromagnetic wave to the separator roll; and a sensor section configured to detect the electromagnetic wave that the radiation source section emits to the separator roll
Data Source
AI summary
To carry out accurate defect inspection over a wide area, a defect inspection device includes: a radiation source section configured to emit an electromagnetic wave to a separator roll; and a sensor section configured to detect the electromagnetic wave that the radiation source section has emitted to the separator roll, the sensor section being configured to detect the electromagnetic wave before and after the separator roll is moved relative to the radiation source section.