Tilted Sensor Camera Alignment for Battery Electrode Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery manufacturing, existing camera systems require two independent cameras to capture positive and negative electrode features, which are prone to misalignment due to continuous vibration, leading to accumulated errors and substandard battery cell production.
Innovation Solution
A winder system with a camera apparatus using a single camera, where the angle between the sensor target plane and the lens plane is set to a predetermined angle greater than 0 degrees and less than or equal to 20 degrees, allowing concurrent focusing on different working planes, and a connecting module to prevent relative position offset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two independent cameras are used to capture positive and negative electrode features, then the features can be detected, but the relative position and angle between cameras change due to continuous vibration, causing accumulated errors
Solution Approach 1:
The patent merges the function of two independent cameras into a single camera system. By using one camera to capture both positive and negative electrode features simultaneously, the system eliminates the relative position and angle changes between multiple cameras caused by vibration, thereby resolving the measurement precision and reliability contradiction.
Solution Approach 2:
The single camera is designed to perform multiple functions: capturing features of both positive and negative electrodes, as well as separators, within a single imaging system. This multi-functional approach replaces the need for multiple specialized cameras, improving both detection precision and position stability.
2Device complexity
If a single camera is used to capture both positive and negative electrode features, then device complexity is reduced, but the depth of field is insufficient to focus on different working planes simultaneously
Solution Approach 1:
The patent introduces a tilting mechanism that changes the orientation of the camera's imaging plane relative to the lens plane. By adjusting the angle between the sensor plane and the optical axis, the system extends the effective depth of field to accommodate features on different working planes (positive electrode, negative electrode, and separators at different distances), thereby maintaining focusing precision while using a single camera.
3Manufacturing precision
If the angle between sensor plane and lens plane is increased to expand depth of field, then focusing on different planes improves, but image quality and recognition effect deteriorate
Solution Approach 1:
The patent optimizes the tilting angle parameter within a specific range (greater than 0 degrees and less than or equal to 20 degrees). This parameter change allows the system to achieve sufficient depth of field for focusing on different working planes while maintaining acceptable image quality and recognition effects. The optimized angle balances the conflicting requirements of focusing precision and image quality.
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 clear image capture of both positive and negative electrode features with a single camera, maintaining steadiness and reducing misalignment errors, thus ensuring high-quality battery cell production.
Implementation Method 1
a camera and a lens, where an angle between a sensor target plane of the camera and a lens plane of the lens is a predetermined angle
Implementation Method 2
A distance (such as 100 mm) between the different working planes is far greater than a depth of field (such as 5 to 15 mm) of a conventional camera
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Embodiments of the present disclosure provide a camera apparatus and a winder system. The camera apparatus includes: a camera and a lens, where an angle between a sensor target plane of the camera and a lens plane of the lens is a predetermined angle, and an angle value of the predetermined angle is greater than 0 degree and less than or equal to 20 degrees. The camera apparatus according to the present disclosure can implement focusing of images on different working planes, thereby obtaining clear images of both positive electrode features and negative electrode features concurrently with a single camera.