Tab Ultrasonic Welding Detection Calibration for Reliability Checks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tab ultrasonic welding detection systems lack reliability checks, leading to the production of defective battery products when their reliability deteriorates.
Innovation Solution
A tab ultrasonic welding detection system equipped with a calibration block, cameras, strip-shaped light sources, and an upper computer that performs both hardware and software checks to ensure reliability, using film sheets with varying grayscale values and radii to identify defects and adjust operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection system operates without reliability checks, then productivity is maintained, but reliability deteriorates leading to defective products
Solution Approach 1:
The system performs preliminary reliability checks using calibration blocks with known defect patterns before actual production detection. The upper computer executes predetermined check programs that verify camera, light source, and software functionality in advance, ensuring the detection system is reliable before processing real battery tabs, thus preventing defective products without impacting overall productivity
Solution Approach 2:
The detection system performs self-diagnosis and self-verification through automated check programs. The upper computer automatically tests hardware components and software algorithms using calibration blocks, enabling the system to verify its own reliability without external intervention, maintaining both reliability and productivity
2Reliability
If comprehensive hardware and software checks are implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The calibration block serves multiple functions: it calibrates the detection system, verifies camera functionality, tests light source performance, and validates software algorithms. This multi-functional design allows comprehensive reliability checks without adding separate test devices, thus improving reliability while minimizing the increase in device complexity
Solution Approach 2:
The calibration block acts as an intermediary object that mediates between the detection system and the reliability verification process. By using this intermediate calibration standard with known characteristics, the system can comprehensively test hardware and software components without direct complex interactions, simplifying the overall system structure while maintaining thorough check capabilities
3Reliability
If targeted debugging is performed based on separate hardware and software check results, then reliability is improved, but loss of time occurs during debugging
Solution Approach 1:
The reliability check process is segmented into distinct hardware checks and software checks that can be independently executed and evaluated. The upper computer separately determines hardware check results and software check results, allowing targeted debugging of specific components rather than comprehensive re-testing, thus improving reliability while minimizing debugging time loss
Data Source
AI summary
A detection system includes a calibration block, a first camera, a second camera, a first strip-shaped light source, a second strip-shaped light source, and an upper computer. A first film sheet and a second film sheet are attached to surfaces of a first tab profiling body and a second tab profiling body of the calibration block, respectively. The first camera and the second camera are used to capture detected images of the first film sheet and the second film sheet, respectively. Both the first strip-shaped light source and the second strip-shaped light source are configured to simultaneously illuminate the first tab profiling body and the second tab profiling body. The upper computer is configured to determine hardware check results according to the detection images, and is further configured to determine a software check result of a visual detection software within the upper computer according to a preset tab state image.