Inline metrology for lithium battery electrodes锂电极片在线 CCD 测量

Every edge.
Every micron. 每一条边，
都量到微米。

Two 20-megapixel cameras photograph both faces of the electrode at once. Software finds every boundary (tab, ceramic, coating, margin) and reports widths and top-to-bottom misalignment in millimetres, to three decimals. 上下两台 2000 万像素相机同时拍摄极片正反面，软件自动找出极耳、陶瓷、涂层、留白的每一条边，输出各段宽度与上下面错位，精确到 0.001 mm。

Talk to us联系我们→ See how it measures看它怎么测
Raw 20 MP frame of an electrode edge from the top camera
CERAMIC 2.967mm
COATING EDGE ∠89.2°
CAM·UP #02 · y=532.698 mm
5472 × 3648 · 138.95 px/mm
x = 0000 px · 00.000 mm
ACQUIRE
0µm / px

Native resolution, 20 MP camera2000 万像素相机单像素精度

0faces面

Top & bottom imaged simultaneously上下相机同步拍摄

0µm

Worst cell error, 1 mm chessboard check1 mm 棋盘格点检最大偏差

0mm

Reported precision on every segment每段宽度输出精度

01

How it sees an edge它如何找到一条边

Below is one real frame from the line, run through the software step by step.以下是产线上的一张真实图像，逐步走一遍软件的处理流程。

Raw frame Horizontal gradient magnitude Annotated result Annotated result
01 / CAPTURE
  1. 01

    Capture采集

    A 5472 × 3648 grayscale frame is taken at a known encoder position. Each file carries its Y coordinate in microns, so frames can be stitched along the web.在已知编码器位置拍下一张 5472×3648 灰度图，文件名自带 Y 坐标（µm），用于沿带材方向拼接。

  2. 02

    Gradient梯度

    Gaussian smoothing, then the horizontal Sobel gradient. Wrinkles in the foil light up faintly, while true material boundaries stand out as bright, continuous lines.高斯平滑后取水平 Sobel 梯度。箔材褶皱只有微弱响应，真正的材质分界则是连续的亮线。

  3. 03

    Peaks & material峰值与材质

    Collapsing the gradient to a 1-D profile gives peaks at candidate edges, which non-maximum suppression thins out. Brightness on each side then identifies the material: coating, ceramic, bare metal, or background.将梯度压成一维曲线，非极大值抑制留下候选边；再按两侧灰度判定材质（涂层、陶瓷、金属或空白）。

  4. 04

    Fit & measure拟合与测量

    RANSAC fits a straight line to each edge and reports its angle. Edges are assigned roles by topology, overlapping fields of view are de-duplicated, and pixels are converted to millimetres using the chessboard calibration.RANSAC 拟合每条边的直线并给出角度；按拓扑关系分配角色，去除视场重叠，最后用棋盘格标定的比例尺换算为毫米。

02

The machine设备

A floor-standing inspection station that drops into an existing coating or slitting line. Shielded camera housings, a stainless work surface, and an operator console with E-stop and keyed controls.落地式检测工位，可直接接入涂布或分切产线：封闭式相机罩、不锈钢工作台面、带急停与钥匙开关的操作台。

CCD Inspector station, front view
Front view正视图
Operator console with indicator buttons and emergency stop
Operator console操作台
Three-quarter view showing camera housing and stainless worktop
Camera housing & worktop相机罩与台面
Three-quarter front view of the station
Three-quarter view侧前视图

03

What it measures测量项

A real double-coated cathode with ceramic edges. Every segment, both faces, and how far the top and bottom coatings are offset from each other. Hover over a segment to see its value.一片真实的双涂层含陶瓷边极片：每一段宽度、正反两面，以及上下涂层的相对错位。鼠标悬停查看数值。

Total length总长 389.951 mm
Tab / foil极耳 / 金属 Ceramic陶瓷 Coating涂层 Margin留白 Misalignment错位

Interactive · base values from a real cathode交互演示 · 基准值取自真实阴极片

Top and bottom never line up. It doesn't matter.上下相机永远不会完全对齐。没关系。

Camera mounts drift and the web wanders, so the two cameras never see the same spot. Most systems subtract a fixed registration constant, which silently mixes camera offset into the result. CCD Inspector measures both faces from the same physical foil edge, so camera offset cancels out and only the true coating offset remains.相机支架会漂移，带材会跑偏，上下两台相机看到的位置永远对不齐。常见做法是减一个固定的配准常数，相机偏移就悄悄混进了结果。CCD Inspector 让两个面都从同一条物理箔边起算：相机偏移被完全抵消，剩下的只有涂层真实的上下错位。

Edge x in bottom image下相机图中边的像素位置—changes with camera随相机变化
Reported misalignment Δ输出的错位 Δ+0.032 mmcamera shift cancelled相机偏移已抵消

Tab width极耳宽度

Outermost foil, found from where the material sits in the frame.由拓扑定位的最外侧金属箔。

lug

Ceramic width陶瓷宽度

Both sides of every coating lane. Down to ~1.6 mm on slit cathodes.每道涂层两侧，分切阴极可测至约 1.6 mm。

glug

Coating width涂布宽度

Supports 1–4 coating lanes per web.支持单片 1–4 道涂层。

coat

Gap & margin间隙与留白

Intermittent gaps and the bare-foil margin between lanes.间歇涂布间隙、道间金属留白。

space · blank

Top / bottom offset上下错位

Left- and right-edge offset per lane, signed, in mm.每道左右缘的有符号错位（mm）。

diff

Edge angle边缘角度

Straightness and skew of each fitted line, in degrees.每条拟合直线的倾角（°），反映走偏与切边质量。

∠89.2°

04

The software软件

These are screenshots of the actual application, measuring real production data.以下均为软件实际运行截图，测量的是真实产线数据。

Measurement view with 12 annotated thumbnails Measurement view with 12 annotated thumbnails Result panel with top, bottom and misalignment data plus schematic Result panel with top, bottom and misalignment data plus schematic Slit single-edge cathode measured on a 12 MP camera Slit single-edge cathode measured on a 12 MP camera Single-lane cathode with ceramic Single-lane cathode with ceramic Software settings Software settings
Full-resolution annotated frame: tab, ceramic and coating edges Full-resolution annotated frame: tab, ceramic and coating edges
Full-resolution frame. Tab, ceramic and coating edges, each with its fitted angle.原图分辨率：极耳、陶瓷、涂层三条边及各自拟合角度。
Length schematic generated by the software Length schematic generated by the software
Length schematic, generated by the software for every measurement.软件为每次测量自动生成的测长图示。

05

Calibration you can audit可复核的标定

A precision 1 mm chessboard sets the pixel scale for each camera, and five cells are re-measured as a check. If any cell drifts beyond tolerance, the result is NG and the line knows before a single electrode is measured. These numbers come from the current reference.以 1 mm 精密棋盘格确定每台相机的像素比例尺，并复测 5 个格子做校验。任一格超差即判 NG，在测量第一片极片之前就能发现问题。以下为当前基准的真实数据。

CAM · UP 138.95 px/mm

5 sampled cells · width / height (mm)5 格采样 · 宽 / 高 (mm)

mean cell平均格宽
0.99942 mm
distortion畸变分
0.0034

max deviation最大偏差 5.99 µm OK

CAM · DOWN 144.24 px/mm

5 sampled cells · width / height (mm)5 格采样 · 宽 / 高 (mm)

mean cell平均格宽
0.99904 mm
distortion畸变分
0.0001

max deviation最大偏差 4.15 µm OK

  • FirstCheckMeasure 5 cells and write the scale as the new reference量 5 格并写入新基准
  • jiaoyanPeriodic standard-plate check. Never moves the reference定期标准片体检，不改基准
  • CalibrateCompare against reference, return OK/NG and drift对比基准，返回 OK/NG 与漂移量
  • Film plateLength-error check with a ruler or film plate菲林板 / 尺子测长误差点检

06

Speaks your line's language直接对接产线上位机

A plain TCP socket and a small text command set. The PLC or host PC sends a recipe and a folder, then asks for the result. Each reply is structured JSON. This is the exact exchange for the electrode above.普通 TCP 连接，一套简单的文本指令：上位机下发配方和目录，再请求结果，回复为结构化 JSON。以下就是上面那片极片的真实报文。

tcp://line-host:8989● LIVE

  


  

    
TCP / IPClient mode, auto-reconnect客户端模式，自动重连

    
UTF-8 · GBKConfigurable encoding & terminator编码与终结符可配

    
JSONResults, calibration, film checks测量 / 标定 / 菲林结果

    
CLIScriptable calibrate · edge · measure命令行 calibrate · edge · measure

  







  

    
07

    
Built for real electrodes为真实极片而生

  

  

    

      
Cathode, double-coated + ceramic阴极 双涂层含陶瓷Ceramic, coating and tab on both faces陶瓷、涂层、极耳，正反两面

    

      
Anode, 3-lane阳极 3 道Coating-to-foil edges through heavy wrinkles褶皱严重的箔材上照样找准涂层边

    

      
Slit, single edge分切单边极片12 MP cameras, ~80 px/mm1200 万像素相机，约 80 px/mm

    

      
Validated on已验证

      
    
        
  • Anode, 3-lane, no ceramic阳极 3 道 无陶瓷
    • 
        
  • Cathode, 2-lane with ceramic阴极 2 道 含陶瓷
    • 
        
  • Single-lane anode / cathode单道 阳极 / 阴极
    • 
        
  • Single-film zone products单膜区产品
    • 
        
  • Slit electrodes, with / without ceramic分切极片 含 / 无陶瓷
    • 
        
  • Film-plate length verification菲林板测长校验
    • 
      

    

  







  

    
08

    
Specifications技术参数

  

  

    
Cameras相机
2× area-scan, top + bottom面阵相机 ×2（上 + 下）

    
Sensor分辨率
20 MP 5472×3648 · 12 MP 4096×3000

    
Pixel scale像素当量
≈ 139–144 px/mm (20 MP) · ≈ 79–84 px/mm (12 MP)

    
Output precision输出精度
0.001 mm

    
Measured测量项
Tab, ceramic, coating, gap, margin, total length, top/bottom offset, edge angle极耳、陶瓷、涂层、间隙、留白、总长、上下错位、边缘角度

    
Coating lanes涂层道数
1 – 4

    
Calibration标定
1 mm chessboard, 5-cell OK/NG check1 mm 棋盘格，5 格 OK/NG 校验

    
Interface接口
TCP/IP (default port 8989), JSON payloads, CLITCP/IP（默认 8989 端口）、JSON 报文、命令行

    
Host OS系统
Windows 10 / 11 x64

    
Licensing授权
Node-locked, offline activation (Ed25519). No internet needed on the line.节点锁定、离线激活（Ed25519），产线无需联网

  

  
Our principle: report the physical width, never a number tuned to agree with another instrument.我们的原则：输出真实的物理尺寸，绝不为了迎合别的仪器去凑数。







  

  

    
See it measure
your electrodes.用您的极片，
现场测给您看。

    
Send us a few sample images or a roll spec. We'll run them through the system and send back the full report.发来几张样片图像或产品规格，我们用系统跑一遍，把完整报告发给您。

    

      chenxu1098@gmail.comchenxu1098@gmail.com→
      Customer license portal客户授权平台