Battery Cover Flatness and Height Measurement

Project Background

Measurement Background

With the rapid development of new energy vehicles, consumer electronics, and other fields relying on high-performance battery systems, the quality requirements for battery components are increasingly stringent. As a key component in the battery structure, the flatness and height accuracy of the battery cover are directly related to the battery's safety performance, sealing effect, and overall assembly quality. Any slight deviation may lead to serious issues such as internal short circuits and leakage of the battery, thereby affecting product reliability and user safety.

Therefore, to ensure that every factory-delivered battery meets the highest quality standards, manufacturers need to introduce a precise and efficient detection system for the flatness and height of battery covers. This system aims to achieve strict monitoring of key dimensional parameters of battery covers through automated means, ensuring product consistency and reliability.

Camera Selection

Shenshi SR7080

Measurement Items

Flatness of the battery cover surface and heights of the positive and negative electrodes

Solution

AI-Vision first locates the point cloud image, then determines the reference plane of the battery surface to measure the surface flatness, and finally measures the heights of the positive and negative electrodes respectively.

Design Concept

Execution Effect Display

• Project Result Display
  • Detection Results

Project Process

1. Initialization

Use the Load Point Cloud tool to load the point cloud image to be processed.

2. Preprocessing

Position Adjustment

1. Use the 3D Square Probe tool to find the lower edge line and left edge line of the battery point cloud respectively.

2. Use the 3D Geometric Intersection tool to calculate the intersection point of the two lines detected in the previous step.

   

3. Use the 3D Position Adjustment tool to adjust the positioning to the intersection point of the two lines.

   

Plane Fitting

1. Use the Create ROI tool to frame the reference area ROI.

2. Use the 3D Plane tool to fit a plane based on the ROI area selected by the Create ROI tool and set it as the zero plane.

   

Copy IM for Different Subprogram Calls

Copy IM1 to IM2 and IM3: Copy IM1 to IM2 and IM3 for measuring the cover flatness and heights respectively.

Tip

When using parallel subprogram calls, each subprogram needs to be executed in a different IM.

3. Cover Flatness and Height Measurement

Cover Flatness Measurement

1. Use the Create ROI Array tool to frame the ROIs of the positions where flatness needs to be measured according to the drawing.

2. Use the 3D Region Operation tool to bind the ROIs framed by the Create ROI Array tool and integrate them into a single region.

3. Use the 3D Flatness tool to bind the region output by the 3D Region Operation tool and calculate the flatness information.

4. Use the Variable Setting tool to add a compensation value to the flatness value and set it to a global variable.

Tip

The compensation value is added according to specific requirements; Global variables need to be manually set in the global variables section;

5. Use the Conditional Branch tool to determine whether the flatness information is within the threshold. Display OK or NG data respectively when it is within the threshold or not.