Inspection solutions for battery cell production

  • 100 % inspected cells for perfect detection and classification
  • Inspection of material quality over the entire web length and width
  • Reduced operational costs and streamlined manufacturing processes
  • Utmost product safety to avoid recalls and incidents
  • Minimized waste, reduced raw material and energy consumption
Vision solutions for ev battery

Automated inspection for battery cells

Battery technology, which is expanding rapidly worldwide, forms the core of several innovative future technologies. In particular, the lithium-ion battery, with its high energy density, has established itself as the leading electricity storage technology in recent years. Without the powerful lithium-ion batteries, there would be no electric cars (EV's), smartphones, laptops. As production errors and safety failures cannot be completely ruled out in this context, meaning that recalls make the headlines from time to time. Product liability cases can then quickly become a financial liability and also cause damage to the company's image.

The high-precision SMASH inspection system ensures consistency throughout the entire value chain - from coating to slitting/cutting to winding/unwinding.

Separator film inspection

The separator film is an indispensable component of the lithium-ion battery. This membrane separates the anode and the cathode, thus enabling the lithium ions to be exchanged. The separator is also an essential safety element to prevent a short circuit in the battery and plays a key role in the speed and lifetime of the cells.

After extrusion, stretching, and coating, the sophisticatedly treated material of the separator film must be carefully inspected to ensure 100% product quality and safety.

The ISRA VISION way to optimal detection

During separator film production, the ISRA VISION camera system detects and classifies the smallest defects in real-time at full web speed. In addition, ISRA's advanced real-time MultiScan High-Dynamic-Range (HDR) technology enables high contrast inspection to detect even thin spots and holes. ISRA VISION's inline inspection systems also inspect the films in the downstream stages of the process chain, such as the slitting units or the rewinder.

Benefits

  • 100% inspection and defect classification
  • Inspection of material quality over the entire web length and width
  • Avoidance of critical defects that can lead to a short circuit and fire
  • Condition/health monitoring to achieve 100% monitoring of the process and the system itself
  • Flawless material for the next process step
  • Waste is reduced, and marketable production volume is increased
  • Plant operators can make product changes efficiently and cost-effectively
  • Product properties are fully monitored and documented
  • 100 % inspection of hole defects with advanced classification
  • Monitoring of PVDF-coating quality
  • High Dynamic Range technology (HDR) to distinguish between holes and thin spots
  • Real-time web inspection camera and intelligent high performance LED 
  • Compliant to highest battery standards
  • New dual exposure technology: Differentiation between holes, missing coating, gels, contaminations, and black spots with utmost precision, done by smart dual exposure mode
  • Holes
  • Metal particles
  • Slitting defects
  • Thin spots 
  • Coating defects
  • Oil drops
  • Black spots
  • Water drops 
  • Large scratches
  • Repeating defects
  • Line speed: 120 – 250 m/min.
  • Line width: Main Lines: 4500 – 7000 mm
  • Line width: Slitting Lines: 1200 – 1400 mm
  • System resolution:  50-100µm 

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SMASH boosts lithium battery film production

Discover the success story of Dezhou Donghong Film Making Technology Co. Ltd., as they overcome the challenges of maintaining stringent quality standards in the booming Chinese electric car market. Learn how the SMASH system not only identified micrometer-sized defects but also increased production speed by over 60 meters per minute. Download the full success story now for insights into the future of precision manufacturing!

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Electrode coating inspection

High-performance battery electrodes are a critical component of lithium-ion cells. The coated electrode materials for cathodes and anodes have to meet high requirements for energy efficiency, storage density, and safety.

Especially after the demanding processing in the roll press, the aluminum and copper-coated electrode foils have to undergo precise quality inspection. The production goal is to achieve a particularly smooth and closed coating as well as 100%-layer detection of both coating surfaces.

The ISRA VISION way to optimal detection

The SMASH inspection system reliably detects the entire material quality for damage such as streaks, holes, impurities, and air bubbles. Additionally, precise edge detection and alignment within the calender are guaranteed.

Benefits

  • 100% inspection and defect classification
  • Inspection of material quality over the entire web length and width
  • Avoidance of critical defects that can lead to a short circuit and fire
  • Condition/health monitoring to achieve100% monitoring of the process and the system itself
  • Flawless material for the next process step
  • Waste is reduced, and marketable production volume is increased
  • Plant operators can make product changes efficiently and cost-effectively
  • Product properties are fully monitored and documented
  • 100% defect detection and classification
  • Real-time-measurement of alignment for utmost coating precision
  • All-in-One-high-speed Camera with highly optimized LED illumination
  • Highly accurate coated area alignment measuring 
  • Alignment monitoring: top to bottom in CD and MD
  • Robust frames for every environment
  • SMASH is robust against dark/bright changes in the material (between electrode and membrane)
  • Track and Trace on single electrode level (optional) 
  • Real-time Multi-Line monitoring and reporting solution with EPROMI 2.0
  • Missing coating
  • Damages of coating
  • Spots from contaminations pressed into coating during calendering
  • Scratches 
  • Coating spots on the edges
  • Edge cracks
  • Wrinkles
  • Scratches and flaws in the coating 
  • Foreign particles
  • Holes / Pinholes
  • Web width: 300 – 1000 mm
  • Line speed: Typical 50 m/min
  • Resolution: 25 - 100 µm

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Innovating battery assembly en

Innovating battery assembly en
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Inspection of lithium-ion battery cells

High-performance battery cells come in three different designs: Pouch cells, cylindrical cells, and prismatic cells. Since these cells are densely packed in battery assemblies for electric vehicles, the quality and integrity of the battery cells directly affect the road safety of electric vehicles.

Recalls due to defective cells are costly and can significantly impact an automaker's brand reputation. Therefore, battery suppliers and manufacturers of electric vehicles have a great interest in 100% product testing and complete documentation.

The ISRA VISION way to optimal detection

ISRA VISION has developed an innovative solution for the inspection of battery cells to provide comprehensive process and quality control. This inline and offline inspection solution performs a complete 360° inspection of the cell to ensure 100% inspection and the delivery of only flawless cells. 

In addition to dimensional inspection, the cell inspection also detects surface defects and contamination. The system can also reliably check barcodes and data codes. Automatic camera calibration and an integrated GigE Vision high-speed interface make it particularly easy to set up the inspection system and integrate it into a fully networked smart factory at full production speed.

Benefits

  • 100% inspection and defect classification
  • Inspection of material quality over the entire web length and width
  • Avoidance of critical defects that can lead to a short circuit and fire
  • Condition/health monitoring to achieve 100% monitoring of the process and the system itself
  • Flawless material for the next process step
  • Waste is reduced, and marketable production volume is increased
  • Plant operators can make product changes efficiently and cost-effectively
  • Product properties are fully monitored and documented
  • Detect all surface defects and monitor the dimensions of the cell
  • Reliable classification of defect at corners and edges
  • Different illumination concepts
  • Five side inspection 
  • Detection of 2D / 3D surface defects
  • Dimension check
  • Inspection of Barcodes / OCR
  • Suitable for inspection prior to degassing (= inspection of semi-final pouch) and the inspection of the final pouch after degassing
  • Dents
  • Bumps
  • Scratch
  • Folding defects 
  • Edge cracks
  • Sealing defects
  • Contamination / foreign objects
  • Tact rate at automotive: ca 15ppm
  • Required tact time: 4 Sec.
  • Target defect size:  > 50um

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Technical article quality inspection along the entire process chain en

Technical article quality inspection along the entire process chain en
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technical-article-quality-inspection-along-the-entire-process-chain.pdf
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287 KB
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test123

Innovating battery assembly en

Innovating battery assembly en
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Production analytics - Data-driven efficiency

The web-based production analytics platform allows you to check the system status of all production lines at a glance or analyze production data in detail. With the quality management system, you analyze historical data, monitor current inspection data in real-time, and identify future trends in your production process.

Early detection of production defects

Detect and quickly identify the cause of threshold value violations at every stage of production with live status information and automatic alerts. As a result you can quickly resolve production defects, shorten downtime, and reduce production costs.

Predictive maintenance

You can prevent potential system failures by analyzing real-time data from the sensors and monitoring systems. This allows proactive planning of maintenance, based on the actual condition of the machines, instead of following a fixed schedule. This data-driven approach saves costs through reduced downtime and increased overall productivity, as well as longer production line life. 

Optimization of production

Dashboards allow you to compare production line and product data onsite or remotely, providing key insights for optimization. This enables you to make informed professional decisions along your value chain to increase the product quality as well as profitability. You can continuously track the progress of optimization measures and present them with visualized advanced reports.

Your benefits

  • Time-saving multi-line overviews, one view for all quality-related information
  • Minimize downtime by monitoring system health data
  • Faster reaction to quality issues with quality data monitoring
  • Fast elimination of production defects, reduction of production costs
  • Improved maintenance for reduced downtime, higher overall productivity and longer production line life

Key Features

  • Overview on production data and plant status
  • Live insights from real time data
  • Department oriented dashboards, customer specific adaptations are possible
  • Web-based solution, no client software installation required
  • Threshold monitoring and alerting
  • Open to integrate relevant third-party data and export data to the customer's systems

Service solutions and individual trainings

For the efficient and future-proof operation of your production systems our highly qualified service teams support you globally in all matters. We provide the implementation, maintenance and servicing as well as the analysis and optimization of your systems.

Learn in the ISRA VISION Academy how our competent trainers always keep your employees up to date with the latest knowledge so that system operators, product engineers and quality managers become real inspection experts.

Contact our experts

Bünyamin Camgöz
Surface & Print inspection - Advanced Materials

Albert-Einstein-Allee 36-40
45699 Herten
Germany

Phone: +49 / 2366 / 9300-284

E-Mail: [email protected] 

Buenyamin Camgoez