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.
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.
Features
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
Typical defects
Holes
Metal particles
Slitting defects
Thin spots
Coating defects
Oil drops
Black spots
Water drops
Large scratches
Repeating defects
Technical data
Line speed: 120 – 250 m/min.
Line width: Main Lines: 4500 – 7000 mm
Line width: Slitting Lines: 1200 – 1400 mm
System resolution: 50-100µm
Learn, how Dezhou Donghong Ltd. achieved 100 % battery film inspection with ISRA VISION's SMASH system.
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.
Features
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
Typical defects
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
Technical data
Web width: 300 – 1000 mm
Line speed: Typical 50 m/min
Resolution: 25 - 100 µm
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.
Features
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
Typical defects
Dents
Bumps
Scratch
Folding defects
Edge cracks
Sealing defects
Contamination / foreign objects
Technical data
Tact rate at automotive: ca 15ppm
Required tact time: 4 Sec.
Target defect size: > 50um
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.
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.
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.
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 - quickly, reliably, 24/7.
Visit our service center and request your customized service solution.
Furthermore, 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.
Visit our ISRA VISION Academy and book your individual and scalable trainings.
Surface & Print inspection - Advanced Materials
Albert-Einstein-Allee 36-40
45699 Herten
germany