X-Ray Electrode Alignment Inspection for Stacked Battery Assemblies
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Solution Overview
Problem
Existing methods for inspecting the alignment of electrodes in a stacked electrode assembly of rechargeable batteries are inaccurate and difficult to visualize, affecting the safety and efficiency of battery manufacturing.
Innovation Solution
A system and method utilizing a reference jig and X-ray imaging at multiple angles to calculate the position coordinates of electrode corners, allowing for precise detection of misalignment between positive and negative electrodes by compensating for actual measured positions and angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection of thin plate electrodes is performed, then the inspection process is simple, but the measurement precision and detection accuracy are poor
Solution Approach 1:
The patent replaces visual inspection with X-ray imaging technology. The beam generator emits X-rays that penetrate the electrode assembly, and the beam detector captures the transmitted X-rays to create images showing the internal alignment of electrodes. This substitution of optical detection with X-ray detection enables accurate measurement of thin plate electrodes that are invisible to the naked eye, resolving the contradiction between inspection simplicity and measurement precision.
Solution Approach 2:
The patent introduces a new dimension of detection by using X-ray imaging from multiple angles (first angle and second angle). By capturing images from different dimensional perspectives and reconstructing the three-dimensional positions of electrodes, the system achieves precise alignment detection that cannot be obtained through conventional two-dimensional visual inspection, thereby improving measurement precision while maintaining operational efficiency.
2Measurement precision
If X-ray imaging at multiple angles is performed, then the measurement precision is improved, but the device complexity and inspection time increase
Solution Approach 1:
The patent employs a reference jig with standardized features that serves multiple functions: it provides positioning references for the electrode assembly, acts as a calibration standard for the X-ray imaging system, and enables coordinate transformation between different imaging angles. This multi-functional reference jig reduces the need for separate calibration devices and positioning fixtures, thereby managing device complexity while achieving high measurement precision through multi-angle imaging.
Solution Approach 2:
The patent creates a virtual three-dimensional model (copy) of the electrode assembly by reconstructing coordinates from multiple two-dimensional X-ray images. Instead of physically manipulating the electrode assembly from multiple angles, the system captures images at different angles and computationally reconstructs the three-dimensional positions. This copying approach simplifies the physical inspection process while maintaining high measurement precision through mathematical coordinate transformation.
3Measurement precision
If coordinates are calculated from X-ray images, then the alignment detection accuracy is improved, but the loss of time for data processing increases
Solution Approach 1:
The patent performs preliminary actions by pre-establishing the coordinate system of the reference jig and pre-calculating transformation matrices for different imaging angles. Before actual measurement, the system stores reference coordinate data and processing algorithms. During inspection, the coordinate calculation involves retrieving pre-computed transformation parameters and applying them to the captured images, significantly reducing real-time processing time while maintaining high measurement precision.
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 easy and accurate detection of electrode misalignment, ensuring proper stacking and enhancing the safety and performance of rechargeable batteries.
Implementation Method 1
a beam generator configured to irradiate X-rays at a first angle and a second angle with respect to any one corner of the electrode assembly and the reference jig
Data Source
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AI summary
An exemplary embodiment of the present invention provides a misalignment detecting system including: a reference jig on which an electrode assembly is disposed; a beam generator configured to irradiate X-rays at a first angle and a second angle with respect to any one corner of the electrode assembly and the reference jig; and a calculator configured to calculate position coordinates of a corner of the electrode assembly at the corner of reference jig.