CN112179910B - Real-time detection processing method and system for defects of lithium battery pole piece - Google Patents
Real-time detection processing method and system for defects of lithium battery pole piece Download PDFInfo
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Abstract
The invention discloses a real-time detection processing method for defects of a lithium battery pole piece, which comprises the following steps: s1, acquiring motion information of the pole piece transmitted at high speed by adopting an encoder; s2, triggering the linear array camera to acquire a pole piece image by using an encoder; s3, identifying flaws of the pole piece according to the image characteristics; s4, judging the NG grade of the flaw and recording the position information of the flaw; s5, the defect processing device carries out defect processing operation on the serious defects; the real-time detection and processing system for the defects of the lithium battery pole piece by adopting the method is also disclosed; the invention can automatically classify and process the flaws, eliminate the image and the response delay of the processing device, has high detection precision and good efficiency, and can meet the requirement of real-time detection of high-speed production of the battery pole piece.
Description
Technical Field
The invention relates to a method for detecting and processing defects of a lithium battery pole piece, in particular to a method and a system for detecting and processing defects of a lithium battery pole piece in real time.
Background
At present, the domestic CCD visual detection technology is still in a high-speed development stage, and many workloads which have high detection precision requirements, are severe in detection environment and cannot be finished manually must be replaced by the visual detection technology. When applying visual detection, the real-time detection needs to be considered. Taking defect detection of a lithium battery pole piece as an example, in the process of defect detection and marking treatment, the factors influencing the marking mainly include the resolution ratio (basically ignored) of a camera, external factors (machine shaking/encoder slipping and the like) and the fluctuation of response time in the interaction process of hardware, in the real-time online monitoring process, the distance between the camera and the marking machine is relatively fixed is marked as L, marking identification is executed when the encoder (pulse number) moves away from the fixed distance when the defect position and the original point position of the camera coincide, the image acquisition process is to acquire photoelectric signals through a photosensitive chip, the photoelectric signals on each pixel are converted into digital signals through an A/D converter, the digital signals are processed into digital images to be cached and transmitted to a PC through a transmission line, and the process can be carried out within 50ms when the defect position and the hardware configuration are different (mainly means to acquire one image, The response time of a flaw processing device (such as a marking machine), the communication time of a conventional network port or a serial port and the IO response time), and the flaw detection of the battery pole piece in the prior art has the technical problems of slow response, poor flaw detection precision and poor consistency of the battery pole piece in high and low speed states.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, provides the real-time detection method for the defects of the battery pole piece, can automatically classify and process the defects, eliminate the response delay of an image and processing device, has high detection precision and high efficiency, and can meet the requirement of real-time detection of high-speed production of the battery pole piece.
In order to achieve the aim, the invention provides a real-time detection processing method for defects of a lithium battery pole piece, which comprises the following steps:
s1, collecting the motion information of the pole piece: the lithium battery pole piece is wound around a plurality of rollers to drive the pole piece to move, meanwhile, an encoder is in transmission connection with the rollers, the encoder acquires the motion information of the pole piece transmitted at a high speed, and the encoder converts the transmission distance and the transportation speed V of the pole piece into electronic signals;
s2, image acquisition: triggering the linear array camera by using an encoder to take a picture, scanning the lithium battery pole pieces positioned on the roller line by the camera to acquire images, transmitting image information to an industrial personal computer, taking any position in the images as a reference, recording the reference position of the images as an encoder value C1, and transmitting the encoder value C1 to a controller;
s3, recognizing image defects: identifying flaws of the pole piece according to the image characteristics, if the image has no flaws, directly displaying the image on a screen, and if the image has flaws, analyzing the characteristics of the flaws to judge the types of the flaws;
s4, NG grade judgment: after the type of the flaw is judged in the step S3, further performing NG grade judgment on the flaw, if the flaw judgment result is not serious, sending an alarm signal by the industrial personal computer to inform an operator to stop the machine, if the flaw judgment result is serious, identifying the position coordinate of the flaw in the image, and calculating the position information and an encoder value C1 to convert the position information into an encoder value C2, wherein the encoder value C2 is transmitted to the controller;
s5, defect processing: after the position information of the flaw is identified in step S4, the controller calculates the flaw processing time and feeds back the information to the flaw processing device according to the encoder value C2, the distance L between the flaw processing device and the camera, the response time T of the flaw processing device, and the transport speed V of the pole piece, and the flaw processing device performs flaw processing operation on the serious flaw.
Preferably, the image in the step S2 is based on the top line on the boundary, and the top line position is recorded as the encoder value C1.
Preferably, the pixel equivalents in the X direction and the Y direction of the image in step S2 are set equal.
Preferably, the steps from step S1 to step S2 further include step S1.1:
s1.1, switching a detection scheme: and selecting a proper pole piece detection scheme from the pole piece detection schemes.
Preferably, the step S2.1 is further included between the steps S2 and S3:
s2.1, gray level monitoring: and after the image is collected, carrying out gray level monitoring on the image, if the gray level of the image meets a preset value, directly entering the step S3, if the gray level of the image does not meet the preset value, automatically supplementing light to the pole piece by a light source to improve the brightness of the pole piece, and collecting the image again by the camera until the gray level of the image meets the preset value, and entering the step S3.
Preferably, step S6 is further included after step S5:
and S6, displaying the image with the flaw on a screen, and storing the image with the flaw.
Compared with the prior art, the real-time detection processing method for the defects of the lithium battery pole piece has the beneficial effects that:
the camera carries out continuous flaw detection operation on the battery pole piece at the position of the roller, avoids the influence of the shaking of a machine platform on the image acquisition of the camera on the pole piece, ensures that the flaw position information of the pole piece can be accurately acquired, utilizes the encoder to trigger the camera to take a picture, namely, when the synchronization process of the encoder position and the camera position acquires a first line of image, an IO signal is immediately output to the encoder to be synchronized, the IO signal is irrelevant to the image acquisition fluctuation and only relevant to the IO response time which can finish the signal interaction within 3ms generally, the time of 50ms can be saved, and the marking precision is instantly and greatly improved under different speeds, wherein the method identifies whether the pole piece has flaws according to the gray scale characteristics, has the advantages of accurate identification and high identification efficiency, the position information of the identified flaws is good, and the flaw processing device can carry out automatic flaw processing record on the flaws, according to the pole piece moving speed V collected by the encoder and the response time T of the flaw processing device, the time when the flaw processing device carries out flaw processing operation on the pole piece can be calculated, the response time of the flaw processing device is eliminated, and the flaw processing precision is improved.
The invention also provides a system for detecting and processing defects of the lithium battery pole piece in real time, which comprises the following components:
pole piece motion information acquisition module: the pole piece motion information acquisition module converts the motion information of the pole piece into an electronic signal and simultaneously records an encoder value C1 of an image line signal;
a vision system: the visual system is triggered to work by the pole piece motion information acquisition module, and the visual system acquires position information of image defects and calculates with an encoder value C1 so as to convert the position information into an encoder value C2;
a controller: the controller receives the pole piece motion information of the pole piece motion information acquisition module and the coded value C2 of the visual system and sends a flaw processing time signal to a flaw processing device; preferably, the controller is a PLC controller;
a defect processing device: the flaw processing device carries out flaw processing operation on flaw positions of the pole pieces;
the vision system comprises an image acquisition module, an image flaw identification module, an NG grade judgment module and an image storage module; the image acquisition module is triggered by the pole piece motion information acquisition module, the image flaw identification module identifies whether a pole piece has a flaw according to gray features, the NG grade judgment module is used for timely informing an operator to confirm whether a small-flaw pole piece meets production requirements, and the image display storage module is used for displaying an image on a screen and storing the image on a database in real time.
Preferably, the vision system further comprises a gray scale monitoring module.
Preferably, the vision system further comprises a detection scheme switching module.
Compared with the prior art, this lithium-ion battery pole piece flaw real-time detection reason system's beneficial effect lies in:
the visual system is triggered to shoot through the pole piece motion information acquisition module, the problem that the visual system shoots and transmits to an industrial personal computer firstly in the prior art can be solved, the response time of recording a picture reference code value is responded after the pole piece motion information acquisition module, the accuracy of acquiring the flaw position information of the pole piece is further improved, wherein the visual system identifies whether the pole piece has a flaw or not according to the gray level characteristics, the visual system has the advantages of accurate identification and high identification efficiency, the position information of the flaw is identified accurately, the flaw processing device can automatically process and record the flaw, and the flaw processing device can calculate when the flaw processing device carries out flaw processing operation on the pole piece according to the pole piece motion speed V acquired by the pole piece motion information acquisition module and the response time T of the flaw processing device, eliminate the response time of the flaw processing device and improve the precision of the flaw processing The device has the advantages of eliminating response delay of an image and processing device, along with high detection precision and high efficiency, and can meet the real-time detection requirement of high-speed production of the battery pole piece.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
Fig. 1 is a flowchart of a method for detecting and processing defects of a lithium battery pole piece in real time according to an embodiment of the present invention;
fig. 2 is a schematic diagram illustrating that the first line of the image acquired in step S2 is converted into the encoder value according to the embodiment of the present invention;
FIG. 3 is a schematic diagram of a defect capture step S3 according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of the defect being captured by the minimum bounding rectangle in step S4 according to the embodiment of the present invention;
FIG. 5 is a schematic plan view of a step S5 defect handling process according to an embodiment of the present invention;
fig. 6 is a block diagram of a system for real-time detecting and processing defects of a lithium battery pole piece according to a second embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example one
The invention provides a real-time detection processing method for defects of a lithium battery pole piece, which comprises the following steps of S1-S6 as shown in figure 1:
s1, collecting the motion information of the pole piece: thereby walk around a plurality of with the battery sheet and cross the roller and drive the pole piece and carry out the transportation operation with tensioning, adopt the encoder to be connected with crossing the roller transmission simultaneously, the encoder all turns into electronic signal with the transportation distance and the transport speed V of pole piece.
In step S1, the battery pole piece is continuously defect-detected at the position of the roller, which can prevent the shaking of the machine from affecting the image acquisition of the pole piece by the camera, ensure that the defect position information of the pole piece can be accurately acquired, and ensure the reliability of the defect detection process.
S1.1, switching a detection scheme: selecting a proper pole piece detection scheme from a plurality of pole piece detection schemes, namely configuring the plurality of detection schemes written in advance in different models with different names, so that a user can conveniently manage the product types, wherein the pole piece product with the same type corresponds to one model name, and the product with the same type has different detection requirements and sizes, and needs to set related parameters for distinguishing, thereby forming an independent flaw detection scheme; in addition, three permissions may be set: the system comprises an operator, an engineer and a manager, wherein the operator can only select and control the software operation/stop permission, the engineer can configure the permission of the operator to have the detection parameter setting, the manager has the operation permission of the whole software, different permissions are provided with different initial passwords, and users with different permissions can be newly added and corresponding passwords can be set according to requirements.
S2, image acquisition: and triggering the camera to take a picture by using the encoder, carrying out image acquisition on the battery pole piece positioned on the roller by using the camera, transmitting image information to the industrial personal computer, taking any position in the image as a reference, recording the reference position as an encoder value C1, and transmitting the encoder value C1 to the controller.
Step S2 is specifically that the camera of the conventional art takes a picture and transmits it to the industrial personal computer, the encoder responds the response time of recording the reference encoded value of the picture, i.e. in the real-time on-line monitoring process, the camera position is fixed, the encoder (pulse number) moves a fixed distance to a set position to execute the defect processing identification assuming that the defect position and the camera origin position coincide, the image acquisition process acquires the photoelectric signal through the photosensitive chip, the photoelectric signal on each pixel is converted into a digital signal through the a/D converter, and the digital signal is processed into a digital image to be cached and transmitted to the PC through the transmission line, however, the fluctuation within 50ms exists in the high and low speed acquisition and different hardware configuration, and when the encoder position and camera position synchronization process acquires the first line image, an IO signal is immediately output to the encoder for synchronization, which is equivalent to the fluctuation unrelated to the image acquisition, only relevant with IO response time, IO response time just can accomplish signal interaction in 3ms generally, almost saves 50 ms's time, consequently under the production speed demand of difference, adopts the encoder to trigger the mode that the camera was shot and can guarantee the accuracy of the positional information of flaw, has improved the flaw processing precision in later stage greatly.
Step S2 is more specific, where the camera is a line scan camera, the line scan camera has the characteristic of continuous line-by-line scanning, all coatings on each roll of battery electrode sheet can be scanned and detected from beginning to end, no other situations such as intermittent detection occur, the line scan camera continuously shoots, outputs a picture for image processing every specified number of picture lines, an image frame signal is connected to an input terminal of a controller, the controller is provided with an encoder running with a roller, when the image frame signal is received, the current encoder value is recorded, for calculation, the value in this embodiment is the position value of the first line of the image, as shown in fig. 2, the encoder value of the first line of the first picture is recorded as 12000pulse, the encoder value of the first line of the second picture is recorded as 22000pulse, the encoder value of the first line of the third picture is recorded as 32000pulse, and at this time, the first picture is taken as a research object for detecting defects, the encoder value C1 is 12000 pulse.
Step S2 is further to set the pixel equivalent of the image taken by the camera in the X direction and the pixel equivalent of the image taken by the camera in the Y direction to be equal, so that the taken image is not deformed, the position accuracy of capturing the defect can be ensured, and the accuracy of subsequent processing on the defect can also be ensured.
S3, recognizing image defects: and identifying defects in the image according to the gray features, if the image has no defects, directly displaying the image on a screen, and if the image has defects, capturing the features of the defects to judge the types of the defects. Whether the pole piece has the defects or not is identified according to the gray features, and the method has the advantages of accurate identification and high identification efficiency, wherein the defects of the image are captured and compared with the defect features in the database for analysis, and the types of the defects are identified, as shown in fig. 3.
S4, NG grade judgment: after the type of the flaw is judged in the step S3, further NG grade judgment is carried out on the flaw, if the flaw judgment result is not serious, the industrial personal computer sends an alarm signal to inform an operator to stop the machine, if the flaw judgment result is serious, the position coordinate of the flaw in the image is identified, the position information and the encoder value C1 are calculated to be converted into the encoder value C2, and the encoder value C2 is transmitted to the controller.
Specifically, in step S4, as shown in fig. 3 and fig. 4, when capturing the serious defect feature, the circumscribed minimum rectangular coordinate of the defect is automatically obtained, the coordinate unit is the image pixel coordinate, for example, the coordinate of the upper left corner of the rectangle is (X1:6000, Y1:2000), wherein the X1 coordinate information is collected by the line camera and transmitted to the defect processing device, the width value of the image in this embodiment is 400mm, the resolution of the line camera is 8192pixel, the pixel equivalent Vres in the image moving direction (Y direction) is 400mm/8192pixel is 0.0488mm/pixel, the calculated image Y1 coordinate corresponds to the actual physical distance L23 73y 1 Vres is 2000pixel 5 mm/pixel is 97.6mm, the pulse equivalent Eres in the encoder rotates one circle and the number of pulses is 200mm/8000 mm, and the calculated image Y equivalent Eres in the image Y direction is equivalent 27 mm/025 mm, thus the calculated position of the serious defect can be converted into the peripheral length C12035 mm/8000 mm, and the calculated position can be converted into the serious defect information C12035/3 mm, and the calculated result can be converted into the serious defect position C3/3 15904pulse, the encoder value C2 is transmitted to the controller.
S5, defect processing: after the position information of the defect is identified in step S4, the controller calculates the defect processing time and feeds back the information to the defect processing device according to the encoder value C2, the distance L between the defect processing device and the camera, the response time T of the defect processing device, and the transportation speed V of the pole piece, and the defect processing device performs defect processing operation on the serious defect.
Specifically, in step S5, as shown in fig. 5, when the mounting distance L between the camera and the defect processing apparatus is known (assuming that the distance therebetween is 3m), the encoder value C3 is obtained by conversion while ignoring the response time of the defect processing apparatus:
C3＝L/Eres＝3m/0.025mm/pulse＝120000pulse；
if the transport speed of the pole piece is fast, the speed compensation correction must be carried out on the encoder value C3: the defect processing device has a relatively fixed time delay from the receipt of the defect processing signal to the contact of the label paper with the coating or pole piece material. For example, 20 marking or code spraying speeds in 1 second, the time from the defect processing action to the contact of the label to the material is about 50ms, and due to the existence of the action time, the defect processing position deviates from the ideal position under different speeds, and particularly when the production speed is high, the precision of defect processing in the conventional technology is poor, so that the controller calculates the current transportation speed V of the battery pole piece in real time through the encoder, sets the compensation time T according to the response time of the defect processing device, calculates the deviation distance to be S-V-T, and calculates the corrected code value C3 according to C3-L-S/Eres, thereby ensuring the precision of defect processing of the defect processing device on serious defects.
And S6, displaying the image with the flaw on a screen, and storing the image with the flaw. Specifically, the image with the flaw characteristics can be displayed on a software interface window in real time and also stored under an appointed folder according to a naming format appointed by a user, the result of flaw classification statistics is named by a suffix name, the CSV file is stored under the appointed folder in real time, and the stored local data is convenient for the user to observe and trace the flaws.
In the method, a camera carries out continuous flaw detection operation on a battery pole piece at a position of a roller, the influence of shaking of a machine on image acquisition of the pole piece by the camera is avoided, the flaw position information of the pole piece can be accurately acquired, the camera is triggered to take a picture by utilizing an encoder, namely, when the first line of image is acquired in the encoder position and camera position synchronization process, an IO signal is immediately output to the encoder for synchronization, the IO signal is irrelevant to image acquisition fluctuation and only relevant to IO response time, the IO response time can be generally finished within 3ms, 50ms of time can be saved, marking precision is instantly and greatly improved under different speeds, wherein the method identifies whether the pole piece has flaws according to gray characteristics, has the advantages of accurate identification and high identification efficiency, the position information of the identified flaws is good, and a flaw processing device can carry out automatic flaw processing and recording on the flaws, according to the pole piece moving speed V collected by the encoder and the response time T of the flaw processing device, the time when the flaw processing device carries out flaw processing operation on the pole piece can be calculated, the response time of the flaw processing device is eliminated, and the flaw processing precision is improved.
Wherein the above steps between S2 and S3 may further include step S2.1:
s2.1, gray level monitoring: and after the image is collected, carrying out gray level monitoring on the image, if the gray level of the image meets a preset value, directly entering the step S3, if the gray level of the image does not meet the preset value, automatically supplementing light to the pole piece by a light source to improve the brightness of the pole piece, and collecting the image again by the camera until the gray level of the image meets the preset value, and entering the step S3.
Step S2.1 is specific, in order to avoid unnecessary brightness adjustment of the light source due to user operation abnormality and other irresistible abnormality, a hook button for brightness adjustment and non-adjustment of the light source is added to the detection scheme, the user can start the brightness adjustment of the light source when a product with a replaced raw material is produced, the gray scale range of an image shot by the camera is 0-255, when the image is at a middle gray scale value of about 120, the defect recognition is most beneficial, and the gray scale of the image can be changed by adjusting the aperture of the lens, adjusting the exposure time of the camera and adjusting the brightness of the light source. The exposure time is a fixed parameter and is not easy to change due to the influence of the movement speed of the machine; the diaphragm of camera lens belongs to the hardware, often moves the hardware inconvenient too. The brightness of the light source can be adjusted through hardware or software, the brightness of the light source is automatically adjusted in a software adjusting mode in the implementation process of the scheme, the gray scale range of normal detection of images shot by the camera during product detection of different raw materials of a user is met, and defects can be conveniently identified in the subsequent step S3.
Example two
As shown in fig. 6, the present invention provides a real-time detecting and processing system for defects of a lithium battery pole piece, comprising:
pole piece motion information acquisition module: the pole piece motion information acquisition module converts the motion information of the pole piece into an electronic signal and simultaneously records an encoder value C1 of an image line signal;
a vision system: the visual system is triggered to work by the pole piece motion information acquisition module, and the visual system acquires position information of image defects and calculates with an encoder value C1 so as to convert the position information into an encoder value C2;
a controller: the controller receives the pole piece motion information of the pole piece motion information acquisition module and the coded value C2 of the visual system and sends a flaw processing time signal to a flaw processing device; preferably, the controller is a PLC controller;
a defect processing device: the flaw processing device carries out flaw processing operation to the flaw position of pole piece, and the flaw processing device is the labeller in this embodiment, and the labeller marks the mark to the flaw, and the flaw processing device can also be ink jet numbering machine.
The vision system comprises an image acquisition module, an image flaw identification module, an NG grade judgment module and an image storage module; the image acquisition module is triggered by the pole piece motion information acquisition module, the image flaw identification module identifies whether a pole piece has flaws according to gray features, the NG grade judgment module is used for timely informing an operator to confirm whether a small-flaw pole piece meets production requirements, and the image display storage module is used for displaying images on a screen in real time and storing the images in a database.
Specifically, the motion information acquisition module acquires the motion distance and the motion speed V of the battery pole piece through the encoder, the encoder is used for triggering the camera to take a picture, the problem that the camera in the prior art firstly takes a picture and transmits the picture to an industrial personal computer, the encoder then responds to the response time for recording a picture reference code value, the accuracy of acquiring the flaw position information of the pole piece is further improved, the image acquisition module uses a line scan camera to acquire an image, the line scan camera has the characteristic of continuous line-by-line scanning, the coating of each battery pole piece can be detected by scanning from head to tail, other conditions such as intermittent detection and the like cannot occur, the image flaw identification module identifies whether the pole piece has flaws according to the gray level characteristics, the linear scan camera has the advantages of accurate identification and high identification efficiency, the flaw position information is identified well, and the NG grade judgment module is used for timely informing an operator whether the small flaw pole piece meets the production requirement or not, the image display storage module is used for displaying images on a screen in real time and storing the images into the database, so that a user can conveniently observe and trace flaws, the flaw processing device can automatically process and record flaws, and according to the pole piece moving speed V collected by the encoder and the response time T of the flaw processing device, when the flaw processing device performs flaw processing operation on pole pieces can be calculated, the response time of the flaw processing device is eliminated, and the flaw processing precision is improved.
The vision system also comprises a gray monitoring module, in order to avoid unnecessary brightness adjustment of the light source caused by user operation abnormity and other irresistible abnormity, a hook selection button for adjusting and not adjusting the brightness of the light source is added in the detection scheme, the user can start the brightness adjustment of the light source when a product with replaced raw materials is produced, the gray range of an image shot by the camera is 0-255, flaw identification is most facilitated when the image is at the middle gray value of about 120, and the gray of the image can be changed by adjusting the aperture of a lens, the exposure time of the camera and the brightness of the light source. The exposure time is a fixed parameter and is not easy to change due to the influence of the movement speed of the machine; the diaphragm of camera lens belongs to the hardware, often moves the hardware inconvenient too. The brightness of the light source can be adjusted through hardware or software, and the brightness of the light source is automatically adjusted in a software adjusting mode in the implementation process of the scheme, so that the gray scale range of normal detection of images shot by the camera during product detection of different raw materials of a user is met.
The visual system also comprises a detection scheme switching module, and a proper pole piece detection scheme can be selected from a plurality of pole piece detection schemes through the setting of the detection scheme switching module, namely, a plurality of detection schemes written in advance are configured in models with different names, so that a user can conveniently manage the product types, pole piece products with the same type correspond to one model name, and the products with the same type have different detection requirements and sizes and need to be distinguished by setting related parameters to form independent flaw detection schemes; in addition, three permissions may be set: the system comprises an operator, an engineer and a manager, wherein the operator can only select and control the software operation/stop permission, the engineer can configure the permission of the operator to have the detection parameter setting, the manager has the operation permission of the whole software, different permissions are provided with different initial passwords, and users with different permissions can be newly added and corresponding passwords can be set according to requirements.
The system camera carries out continuous flaw detection operation on the battery pole piece at the position of the roller, avoids the influence of the shaking of a machine platform on the image acquisition of the camera on the pole piece, ensures that the flaw position information of the pole piece can be accurately acquired, triggers the camera to take a picture by utilizing the encoder, namely, when the synchronization process of the encoder position and the camera position acquires a first line of image, an IO signal is immediately output to the encoder to be synchronized, which is not related to the image acquisition fluctuation and is only related to the IO response time which can finish the signal interaction within 3ms generally, the time of 50ms can be saved, and the marking precision is instantly and greatly improved under different speeds, wherein, the method identifies whether the pole piece has flaws according to the gray level characteristics, has the advantages of accurate identification and high identification efficiency, the position information of the identified flaws is good, and the flaw processing device can carry out automatic flaw processing record on the flaws, according to the pole piece moving speed V collected by the encoder and the response time T of the flaw processing device, the time when the flaw processing device carries out flaw processing operation on the pole piece can be calculated, the response time of the flaw processing device is eliminated, and the flaw processing precision is improved.
The above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.
Claims (9)
1. A real-time detection processing method for defects of a lithium battery pole piece is characterized by comprising the following steps:
s1, collecting the motion information of the pole piece: the lithium battery pole piece is wound around a plurality of rollers to drive the pole piece to move, meanwhile, an encoder is in transmission connection with the rollers to obtain the motion information of the pole piece transmitted at a high speed, and the encoder converts the transmission distance and the transportation speed V of the pole piece into electronic signals;
s2, image acquisition: triggering the linear array camera by using an encoder to take a picture, scanning the lithium battery pole pieces positioned on the roller line by the camera to acquire images, transmitting image information to an industrial personal computer, taking any position in the images as a reference, recording the reference position as an encoder value C1, and transmitting the encoder value C1 to a controller;
s3, recognizing image defects: identifying flaws of the pole piece according to the image characteristics, if the image has no flaws, directly displaying the image on a screen, and if the image has flaws, analyzing the characteristics of the flaws to judge the types of the flaws;
s4, NG grade judgment: after the type of the flaw is judged in the step S3, further performing NG grade judgment on the flaw, if the flaw judgment result is not serious, sending an alarm signal by the industrial personal computer to inform an operator to stop the machine, if the flaw judgment result is serious, identifying the position coordinate of the flaw in the image, and calculating the position information and an encoder value C1 to convert the position information into an encoder value C2, wherein the encoder value C2 is transmitted to the controller;
s5, defect processing: after the position information of the defect in the step S4 is identified, the controller calculates the defect processing time and feeds back the information to the defect processing device according to the encoder value C2, the distance L between the defect processing device and the camera, the response time T of the defect processing device, and the transportation speed V of the pole piece, and the defect processing device performs defect processing operation on the serious defect, specifically including:
step 1: calculating an offset distance S between the flaw processing position and the ideal position, wherein the offset distance S is as follows:
step 2: the corrected encoder value C3 is calculated, the encoder value C3 is:
wherein L is the distance between the defect processing device and the camera,
is the pulse equivalent of the encoder.
2. The method as claimed in claim 1, wherein the image in step S2 is based on a top line on the boundary, and the top line position is recorded as the encoder value C1.
3. The method as claimed in claim 1, wherein the pixel equivalent values of the image in the X direction and the Y direction are set to be equal in step S2.
4. The method for detecting and processing the defects of the lithium battery pole piece in real time as claimed in any one of claims 1 to 3, wherein the steps from S1 to S2 further include the steps of S1.1:
s1.1, switching a detection scheme: and selecting a proper pole piece detection scheme from the pole piece detection schemes.
5. The method for detecting and processing the defects of the lithium battery pole piece in real time as claimed in any one of claims 1 to 3, wherein the step between S2 and S3 further comprises the step S2.1:
s2.1, gray level monitoring: and after the image is collected, carrying out gray level monitoring on the image, if the gray level of the image meets a preset value, directly entering the step S3, if the gray level of the image does not meet the preset value, automatically supplementing light to the pole piece by a light source to improve the brightness of the pole piece, and collecting the image again by the camera, and entering the step S3 until the gray level of the image meets the preset value.
6. The method for detecting and processing the defects of the lithium battery pole piece in real time as claimed in any one of claims 1 to 3, wherein the step S5 is followed by a step S6:
and S6, displaying the image with the flaw on a screen, and storing the image with the flaw.
7. A real-time detection and processing system for defects of a lithium battery pole piece is characterized in that the real-time detection and processing method for the defects of the lithium battery pole piece, which is disclosed by any one of claims 1 to 6, is adopted, and comprises the following steps:
pole piece motion information acquisition module: the pole piece motion information acquisition module converts the motion information of the pole piece into an electronic signal and simultaneously records an encoder value C1 of an image line signal;
a vision system: the visual system is triggered to work by the pole piece motion information acquisition module, and the visual system acquires position information of image defects and calculates with an encoder value C1 so as to convert the position information into an encoder value C2;
a controller: the controller receives the pole piece motion information of the pole piece motion information acquisition module and the coded value C2 of the visual system and sends a flaw processing time signal to a flaw processing device;
a defect processing device: the flaw processing device carries out flaw processing operation on flaw positions of the pole pieces;
the vision system comprises an image acquisition module, an image flaw identification module, an NG grade judgment module and an image display storage module; the image acquisition module is triggered by the pole piece motion information acquisition module, the image flaw identification module identifies whether a pole piece has flaws according to gray features, the NG grade judgment module is used for timely informing an operator to confirm whether a small-flaw pole piece meets production requirements, and the image display storage module is used for displaying images on a screen in real time and storing the images in a database.
8. The system of claim 7, wherein the vision system further comprises a gray monitoring module.
9. The system of claim 7, wherein the vision system further comprises a detection scheme switching module.
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| CN202010955791.9A CN112179910B (en) | 2020-09-11 | 2020-09-11 | Real-time detection processing method and system for defects of lithium battery pole piece |
| PCT/CN2021/090445 WO2022052480A1 (en) | 2020-09-11 | 2021-04-28 | Method and system for detecting and processing defect in lithium battery electrode plate in real time |
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