Tilted-Sensor Camera Alignment for Battery Electrode Winding
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Solution Overview
Problem
In battery manufacturing, the existing camera systems require two independent cameras to detect the alignment of positive and negative electrode plates, which are prone to misalignment due to continuous vibration, leading to accumulated errors and potential short circuits.
Innovation Solution
A camera apparatus with a single camera and a lens, 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 the camera to focus on different working planes and capture clear images of both positive and negative electrode features concurrently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two independent cameras are used to detect positive and negative electrode features, then both electrode features can be detected, but the system complexity increases and relative position/angle changes due to vibration cause accumulated errors
Solution Approach 1:
The patent merges the function of two independent cameras into a single camera by tilting the sensor target plane relative to the lens plane. This single camera captures images of both the positive electrode (first working plane) and negative electrode (second working plane) features simultaneously, reducing system complexity while maintaining detection capability for both electrodes.
Solution Approach 2:
The patent introduces a spatial dimension by tilting the sensor target plane at a predetermined angle (greater than 0 degree and less than or equal to 20 degrees) relative to the lens plane. This angular dimension enables the single camera sensor to capture light rays from two different working planes (positive and negative electrodes) that would otherwise require separate cameras positioned at different locations.
2Device complexity
If a single camera is used with conventional parallel alignment, then system complexity is reduced, but the camera cannot concurrently obtain clear images of both positive and negative electrode features on different working planes
Solution Approach 1:
The patent tilts the sensor target plane relative to the lens plane by a predetermined angle (greater than 0 degree and less than or equal to 20 degrees), introducing an angular dimension that enables the single camera to capture clear images of both working planes simultaneously. This angular adjustment allows light rays from both the positive electrode and negative electrode to converge properly on the tilted sensor surface.
Solution Approach 2:
The patent changes the geometric parameter of the camera assembly by setting a specific angular relationship between the sensor target plane and the lens plane. This parameter change (the predetermined angle) optimizes the optical path to enable simultaneous clear imaging of both working planes, resolving the focusing precision issue while maintaining single-camera simplicity.
3Manufacturing precision
If the angle between sensor target plane and lens plane is increased beyond 20 degrees, then focusing on different working planes improves, but optical aberrations and image quality deteriorate
Solution Approach 1:
The patent optimizes the angular parameter by setting the predetermined angle between the sensor target plane and lens plane to be greater than 0 degree and less than or equal to 20 degrees. This optimized parameter range achieves sufficient focusing precision for both working planes while avoiding excessive angular deviations that would cause optical aberrations and degrade 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
The solution enables the camera apparatus to obtain clear and concurrent images of both positive and negative electrode features, reducing the risk of misalignment and short circuits, while maintaining steadiness despite continuous vibration.
Implementation Method 1
the angle between the sensor target plane of the camera and the lens plane of the lens is a predetermined angle... the camera apparatus can implement focusing of images on different working planes
Data Source
AI summary
Embodiments of the present disclosure provide a winder system that includes a battery winder and a camera apparatus. The battery winder is configured to wind a positive electrode plate and a negative electrode plate of a battery. 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 the predetermined angle is greater than 0 degree and less than or equal to 20 degrees. The camera apparatus is configured to obtain images of the positive electrode plate and images of the negative electrode plate concurrently. 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.