How to Detect Swollen Prismatic Cells During Sorting?

Detecting Swollen Prismatic Cells in the Battery Sorting Industry
In the battery sorting industry, especially with those batteries using prismatic cells, detecting problems with cells that are swollen is critical to maintaining the quality and safety of the sorted batteries. A swollen cell can be a significant danger both to the equipment and to the eventual customer. This article will detail the dangers of the swollen prismatic cell and how to best detect if a cell has swollen during the sorting process.
Detecting the Swollen Prismatic Cell
Swollen cells are a result of an internal build up of gas that may have released due to overcharging, aging, or simply through defective manufacturing processes. If the swollen cell is not detected prior to the assembly of battery packs, not only will the cell suffer from performance problems but also through danger due to leaks and/or possible fire. It is imperative to detect swollen cells before the cell is used.Primarily, visual detections may be made, as the swollen cell is usually visible “puffed up” or distorting outward through distortion of the outer casing. The swelling may also be indicated by weighing and observing for abnormal weight fluctuations, and some cells may even hiss or pop when; squeezed when swelling occurs, although this may not be a great danger.How This Is Done by Sorting Operators and Equipment in The Factory
As it relates to sorting, there are a number of methods that are all listed for checking for swollen prismatic cells.
Visual Inspection
A visual inspection results in a good number of cells making it through the process, however, clever operators and factory equipment is prepared with a clever eye for anything that looks like a swell from someone’s side serving. The bulge shows through the outer casing that covers the prismatic cells and sometimes this can be sorted out the old-fashion way “by slapping gloves” as in sliding the cells on the conveyer to check the bulge.
Automated Sorting Machines with Image Recognition
Those machines have a multi-prong, or rectangular prongs, image recognition system that checks for bulging prismatic cells that won’t pass inspection from a precision line that feeds the conveyor system. High res cameras mounted in various places, including under the conveyor belt, capt that snap of images of the cells for inspection.
Weight
More of the damsels and gents can be found to be heavier on the standard scale, as swollen cells usually are found to be, as send cells hauling a swbadtooth through the screening process.By employing accurate weight scales as part of the sorting apparatus, you can spot cells that don’t fall within the acceptable weight range.
This method is used in conjunction with some other methods. So swollen cells can be detected without sight.
4. IR Testers
Infrared (IR) testers can also be deployed to determine the thermal performance of the battery cells.
Swollen prismatic cells could give rise to temperature anomalies in both the charge/discharge tests as a result of internal resistance. The temperature difference can be detected, during the sorting process, with an IR sensor.
While the IR testing is not going to be conclusive alone, it can form part of the kit that helps identify cells worth a further inspection and testing.
5. X-Ray
In some sophisticated systems, the cell is examined with x-ray. This could show swelling that is not immediately visible. Abnormalities are set to be flagged in the x-ray image of the prismatic cell, due to gas that has built up inside. This step is essential for the quality of sorting.
Best Practices for Dealing with Swollen Cells
Having detected swollen prismatic cells, the next thing to do is to deal with them appropriately in order to minimize the risk. Here are a few best practices to adhere.
Segregate the Swollen Cells: After detection, the next best thing is to remove the swollen cells from the rest of the batch. In this way only the safe cells will pass through the sorting and assembly process.
Safely Dispose the Defective Cells: The regular swollen cells should be disposed appropriately, according to local regulations, to prevent certain safety hazards. Many recycling centers have procedures in place to appropriately handle somewhat defunct cells.
Proper Testing Equipment: Ensure your sorting machines are equipped with well defined testing equipment with sophisticated image or IR sensors to detect problems such as swelling more aptly.
Regular Maintenance of the sorting equipment: The best way to spot potential defects early on is to regularly maintain your sorting machines and their requisite testing systems. Seek to constantly calibrate all the sensors, cameras and scales for an optimally performing sorting plant.
Detecting swollen prismatic cells in normal sorting is called0 job. If you properly deploy human eyes in ocular, or machine image recognition, weight based detection tests, you could significantly minimize defects making it to the production line.
With the right social and machine equipment, you are assured of optimum detection on your line while protecting the end users. This kind of proactive approach often demands an important place for your products in the battery sorters marketplace.