- From Web to Cell: Envisioning the future of battery inspection
- Separator film inspection
- Inspection of the electrode film
- Cell production: End-of-line inspection for prismatic, cylindrical and pouch cells
- Production analytics - Data-driven efficiency
- Service solutions and individual trainings
- Contact our experts
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.
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
- Typical defects
- Technical data
- 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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Inline quality inspection battery production
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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
- Typical defects
- Technical data
- 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
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Technical article quality inspection along the entire process chain en
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Innovating battery assembly en
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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
- Prismatic Cells
- Pouch Cell
- Cylindrical Cells
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
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
Download additional information
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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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test123
Innovating battery assembly en
- Filename
- innovating-battery-assembly-en.pdf
- Size
- 7 MB
- Format
- application/pdf
test123
Inline quality inspection battery production
- Filename
- inline-quality-inspection-battery-production-en.pdf
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- 3 MB
- Format
- application/pdf
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.
