Automatic Detection of Structural Deformations in Batteries from Imaging data using Machine Learning : Exploring the potential of different approaches for efficient structural deformation detection

Abstract: The increasing occurrence of structural deformations in the electrodes of the jelly roll has raised quality concerns during battery manufacturing, emphasizing the need to detect them automatically with the advanced techniques. This thesis aims to explore and provide two models based on traditional computer vision (CV) and deep neural network (DNN) techniques using computed tomography (CT) scan images of jelly rolls to ensure that the product is of high quality. For both approaches, electrode peaks as keypoints of anodes and cathodes in prismatic lithium battery jelly rolls are detected to extract the geometric features to identify if a particular jelly roll has some structural deformations. For traditional CV methods, the images undergo some pre-processing steps, extraction of foreground through adaptive thresholding, and morphological operations to extract contour edges, followed by applying Harris corner detector to detect electrode peaks. However, this approach shows limitations in detecting small or negative distance differences in deformed images. Furthermore, this study proposes another approach based on supervised transfer learning using pre-trained deep learning models on annotated data. After exploring different architectures, the VGG19 model pre-trained on ImageNet dataset outperformed as compared to other architectures, even with insufficient training data, achieving a maximum accuracy of 93.13 % for 1-pixel distance, 98.87 % for 5-pixel distance and 99.29 % for 10-pixel distance on test data, where the performance metrics, such as Percentage of Correct Keypoint (PCK), Mean-Square Error and Huber loss are utilized. As a result, this baseline proves to be a valuable tool for detecting structural deformations in jelly rolls. Moreover, a GUI-based executable application is developed using both approaches for raising the OK or NG flags for detecting structural deformations in each jelly roll.