Camera-Based Methodology for the Automated Real-Time Assessment of Material Thinning in Battery Cell Manufacturing
摘要
As global demand for electric vehicles and energy storage systems increases, the design and manufacturing of electrochemical batteries play a crucial role in meeting these needs. However, evolving cell designs and high safety requirements pose significant challenges in mass production, leading to high scrap rates and increased energy consumption. Traditional methods for examining the cell interior, such as CT scans and X-rays, are costly and often allow only random quality inspections, resulting in further manufacturing scrap. To address this, we present a method for non-destructive inline measurement of battery case wall thickness during the assembly of cylindrical cells, utilizing a calculation model and an industrial camera system. After the forming process, cell cases are automatically measured and evaluated for critical wall thickness using our model, which is integrated into the machine control system for efficient quality assessment. Our research successfully demonstrates the indirect determination of material thinning through camera-based methods, establishing a correlation between our quality assessment results and experimentally validated product quality, with a Pearson correlation coefficient of 0.94, indicating a strong linear correlation in our evaluated data. This publication presents a novel approach for inline 100% inspection of material thinning during the shaping of cylindrical battery cases, minimizing the reliance on CT scans and X-rays. This method offers significant advantages in production costs, product quality, and sustainability, and can also be applied to other manufacturing processes involving the high-precision reshaping of metallic materials.