Inline quality inspection in battery production

  • 100% inline inspection to control the entire web 
  • 100% inline tested cells 
  • Reduced operating costs thanks to optimized production processes  
  • Maximum product safety to avoid recalls and incidents 
  • Saving of raw materials and energy along the value chain 
Inline battery inspection

Visit us at the Battery Show North America

Oct. 8-10, 2024, Detroit, USA
Huntington Place
Booth 3822 within the German Pavilion

We will present the latest inline quality inspection solutions in battery production to achieve: 

  • 100% inline tested battery materials 
  • 360° inspection of cylindrical, prismatic and pouch cells
  • Reduced operating costs thanks to optimized production processes 
  • Maximum product safety  to avoid recalls and incidents 
  • Saving of raw materials and energy along the value chain
The Battery Show Europe 2024

From Web to Cell: Envisioning the future of battery inspection

In battery production, a high level of precision is required when processing material webs in order to guarantee a safe and high-quality product. To achieve this, manufacturing companies need a suitable basis for decision-making along with accurate data to optimize production and reduce waste.

Battery-inspection-overview-graphic-from web to cell + Atlas Copco

Separator film inspection

Separator film is a component of the lithium-ion battery. This membrane separates the anode from the cathode and thus enables the safe and functional exchange of lithium ions. The separator is also an essential safety element to prevent a short circuit in the battery and increase the service life of the cells.

After extrusion, stretching, and coating, the highly treated separator film must be carefully inspected to ensure 100% product quality and safety. This ensures no defects are present at an early stage in the battery manufacturing process.

Benefits

  • Reliable defect classification through the use of HDR technology: Differentiation between pin holes and thin spots 
  • Inspection and documentation over the entire length and width of the web: Flawless material, Avoidance of critical defects, Increase in productivity 
  • Holistic solution approach for process optimization: From defect data to decision data, Live and analytical dashboards (in-house development), Enabler on the path to Industry 4.0 
  • Black spots 
  • Coating defects 
  • Holes 
  • Large scratches 
  • Metal particles 
  • Oil drips 
  • Repetition error 
  • Slitting defects 
  • Thin spots 
  • Water droplets 
  • Line speed: 120 - 400 m/min. 
  • Line width: up to 7800 mm 
  • Main Line, Coating/Slitting Line: up to 1700 mm 
  • System resolution: 20 - 100 μm 

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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!

dezhou-donghong-thumbnail

Inspection of the electrode film

Meet the high-quality requirements for electrode film throughout the entire production process. High-performance battery electrodes are crucial components of battery cells.

Coated electrode foils for both cathodes and anodes must meet stringent production and inspection standards. The quality of these electrodes directly impacts the performance and safety of each battery cell. 

Coating 
Our inline quality inspection system is vital for verifying adherence to the following criteria: flawless coatings (defect detection + classification), measuring the geometric positions of front and rear sides (measurement), providing accurate quality and measurement data in real-time. Track all quality data along the process-chain (Track & Trace). Communication with other devices (for example for web guidance or 3D measurement) 

Calendering 
After the demanding process of the roller press, the Aluminium and copper-coated electrode foils are subjected to another precise quality inspection. The aim is to achieve a fully homogeneous coating and 100% geometric monitoring. 

Slitting 
During the cutting process, reliable data transfer from the parent roll to the child roll must be ensured. In addition, geometric monitoring of the coated electrode foils is crucial. 

Benefits

  • Reliable defect classification: Use of multiple lighting channels, Self-learning classifier (AI + deep learning), Use of HDR technology 
  • Inspection and documentation over the entire length and width of the web: All-in-one high-speed camera (400 KHz) or CIS-Sensor with 600 or 1200dpi with highly optimized LED lighting, Avoidance of critical errors, Monitoring of error patterns and geometric deviations 
  • Holistic solution approach for process optimization: From defect data to decision data, Live and analytical dashboards (in-house development), Implementation of track and trace strategies 
  • Making an active contribution to sustainability goals: Minimizing waste, reducing raw material and energy consumption 
Graphic-defects-Electrode Coating
  • a) Agglomerate 
  • b) Coating Crack 
  • c) Contamination 
  • d) Micro-compression     
  • e) Mud Crack 
  • f) Pinhole 
  • g) Slip 
  • h) Stripe
  • Line speed: 120 - 400 m/min. 
  • Line width: Main lines: 4500 - 7800 mm, Coating/Slitting: 1200 - 1700 mm 
  • System resolution: 20 - 100 μm 

Download additional information

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Technical article quality inspection along the entire process chain en

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Innovating battery assembly en

Innovating battery assembly en
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Inline quality inspection battery production

Inline quality inspection battery production
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Cell production: End-of-line inspection for prismatic, cylindrical and pouch cells

The rapid pace of innovation in battery applications must not compromise quality. Thus, integrating a cell inspection system is essential for the battery production process. 

The inspection system can be integrated directly into the production line and enables 360° inspection of cylindrical, prismatic and pouch cells. It is typically used before or after the formation and aging process. It detects 2D and 3D surface defects such as dents, dings, scratches, wrinkles, and contamination, for example from electrolytes. The inspection system reliably detects and classifies critical defects on the surface and edge areas and monitors the dimensions and sealing seams of the cells. 

Benefits

  • Inline inspection of battery cells during ongoing production: Inspection of all surfaces including the critical edge areas, Battery format-specific image processing set-up for inline inspection (cycle time 15 ppm and more) 
  • Reliable defect classification: AI-supported anomaly detection of the critical edge areas, Detection of 2D and 3D defects, Monitoring of geometric dimensions 
  • Holistic solution approach for process optimization: From defect data to decision data, Live and analytical dashboards (in-house development), Implementation of track and trace strategies 
  • Making an active contribution to sustainability goals: Waste is reduced and the marketable production volume is increased,  Saving of finite resources, 2nd inspection loop supported by re-work dashboard

Typical defects: 

  • Contamination/foreign objects 
  • Defects in the seal 
  • Dents 
  • Edge cracks 
  • Folding errors 
  • Scratches 
  • Unevenness

Technical data:

  • Cycle rate: approx. 15ppm
  • Required cycle time: 4 sec. 
  • Target defect size: > 50μm 

Typical defects: 

  • Burrs
  • Dents and dings 
  • Deviations from the geometry 
  • Edge deformation and other 
  • Electrolyte residues 
  • Rust and other residues 
  • Scratches

Technical data:

  • Cycle rate: Limited by mechanical transport 
  • Required reaction time: approx. 3 seconds 
  • Target defect size: 50μm

Typical defects:

  • Dent 
  • Edge cracks 
  • Electrolyte residues 
  • Foreign objects 
  • Holes / pinholes 
  • Micro scratches 
  • Scratches 
  • Wrinkles

Technical data: 

  • Cycle rate: approx. 20ppm 
  • Required cycle time: 3 sec. 
  • Target defect size: > 50μm

Download additional information

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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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Innovating battery assembly en

Innovating battery assembly en
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innovating-battery-assembly-en.pdf
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7 MB
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test123

Inline quality inspection battery production

Inline quality inspection battery production
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inline-quality-inspection-battery-production-en.pdf
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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

Vanessa Slaby
Surface & Print inspection - Advanced Materials

Albert-Einstein-Allee 36-40
45699 Herten
Germany

Phone: +49 / 2366 / 9300-475

E-Mail: [email protected]

Vanessa Slaby