Method for Identifying the Degree of Battery Defects by Fusing Dual-Mode Ultrasonic Imaging and Deep Vision

WU Yuran; LI Zexing; WANG Pengbo; SHEN Mengyuan; NIU Jingkai; MIAO Shan

doi:10.19799/j.cnki.2095-4239.2026.0156

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Method for Identifying the Degree of Battery Defects by Fusing Dual-Mode Ultrasonic Imaging and Deep Vision

更新时间：2026-05-07

- Method for Identifying the Degree of Battery Defects by Fusing Dual-Mode Ultrasonic Imaging and Deep Vision
- Energy Storage Science and Technology Pages: 1-12(2026)
- 作者机构：
  
  1.郑州电力高等专科学校，河南郑州450000
  2.郑州大学电气与信息工程学院，河南郑州 450001
- 作者简介：
- 基金信息：
- DOI：10.19799/j.cnki.2095-4239.2026.0156
  CLC： TM 92
- Received：12 February 2026，
  
  Revised：2026-04-21，
  
  Online First：06 May 2026，
- 稿件说明：
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武予然, 李泽星, 王鹏博, 等. 融合双模式超声成像与深度视觉的电池缺陷程度辨识方法[J]. 储能科学与技术, XXXX, XX(XX): 1-12.

WU Yuran, LI Zexing, WANG Pengbo, et al. Method for Identifying the Degree of Battery Defects by Fusing Dual-Mode Ultrasonic Imaging and Deep Vision[J]. Energy Storage Science and Technology, XXXX, XX(XX): 1-12.
武予然, 李泽星, 王鹏博, 等. 融合双模式超声成像与深度视觉的电池缺陷程度辨识方法[J]. 储能科学与技术, XXXX, XX(XX): 1-12. DOI： 10.19799/j.cnki.2095-4239.2026.0156.

WU Yuran, LI Zexing, WANG Pengbo, et al. Method for Identifying the Degree of Battery Defects by Fusing Dual-Mode Ultrasonic Imaging and Deep Vision[J]. Energy Storage Science and Technology, XXXX, XX(XX): 1-12. DOI： 10.19799/j.cnki.2095-4239.2026.0156.

摘要

为解决电池生产、运输及服役全周期的内外部缺陷检测难题，提升缺陷评估的定量化精度与工程实用性，本文提出一种融合双模式超声成像与深度视觉的电池缺陷程度辨识方法。首先，基于超声透射扫描与反射扫描双模式成像技术，结合多工况缺陷电池制备与数据增强方法，以36块样本电池为对象，构建覆盖气泡、磕碰、划痕、附着物、浸润度等典型缺陷的结构化图像数据库。其次，设计基于深度学习与计算机视觉的电池缺陷辨识模型，提出集成残差学习与注意力门控机制的Attention Residual U-Net缺陷分割网络，通过残差块缓解梯度消失问题，借助注意力门控强化缺陷区域特征，实现对电池微小、不规则缺陷的精准分割。通过残差块缓解梯度消失问题，借助注意力门控强化缺陷区域特征，实现对电池微小、不规则缺陷的精准分割。最后，基于Attention Residual U-Net输出的缺陷掩膜，提取区域尺度、连通域聚集状态、线性连续性及空间分布等视觉信息，采用K-means聚类确定各类缺陷的基础分级阈值，并结合层次分析法（AHP）与故障模式及影响分析（FMEA）完成风险修正与权重分配，将综合得分离散化为优质、良好、合格、风险四个质量等级，实现缺陷程度的量化辨识与分级预警。经所构建包含2500余张缺陷图像数据库的实例验证，该方法mIoU为0.8783、Dice系数为0.9328，可精准辨识电池内外部缺陷并量化状态等级，为电池质量管控提供高效可靠的技术支撑。

Abstract

To address the challenges of internal and external defect detection throughout the full life cycle of batteries including production

transportation and service

and to improve the quantitative accuracy and engineering practicability of defect evaluation

this paper proposes a battery defect degree identification method integrating dual-mode ultrasonic imaging and deep vision. Firstly

based on the dual-mode imaging technology of ultrasonic transmission scanning and reflection scanning

combined with the preparation of defective batteries under multiple working conditions and data augmentation methods

a structured image database covering typical defects such as air bubbles

mechanical indentation

scratches

surface attachments

and electrolyte infiltration uniformity was constructed based on 36 sample batteries. Secondly

a battery defect identification model based on deep learning and computer vision is designed

and an Attention Residual U-Net defect segmentation network integrating residual learning and attention gate mechanism is proposed. The residual block is adopted to alleviate the gradient vanishing problem

and the attention gate is utilized to enhance the features of defect regions

so as to achieve accurate segmentation of tiny and irregular defects in batteries. Finally

to realize quantitative identification and graded early warning of defect severity

the defect thresholds

score mapping rules

and weight allocation are quantified based on K-means clustering

Analytic Hierarchy Process (AHP)

and Failure Mode and Effects Analysis (FMEA). Specifically

K-means clustering and normal distribution fitting are used to determine the natural thresholds of defect pixel areas; AHP is applied to quantify the impact weights of different defects; FMEA is adopted to analyze the failure modes

severity

and occurrence probability of each defect

and the score mapping rules are formulated to map defect parameters to quantitative scores. The comprehensive score is then discretized into four quality levels: Excellent

Good

Qualified

and Risk

realizing hierarchical early warning of battery states Verified by the constructed database containing more than 2500 defect images

the proposed method achieves a mIoU of 0.8783 and a Dice coefficient of 0.9328. It can accurately identify internal and external battery defects and quantify state grades

providing efficient and reliable technical support for battery quality control.

关键词

Keywords

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