Vision solutions for battery cell manufacturing

High performance & speed
Innovative, high-performance camera technology for state-of-the-art production methods
Durable & reliable
With the lowest failure rate in the industry, our camera systems stand for reliability in 24/7 operation
Simple integration
All of our components are compatible and easy to connect to target systems using pylon software
Availability & reliable delivery
Stable supply chains ensure long-term availability of our products and prevent production downtime

Find out in our webinar:

How machine vision is used for quality control in the production of battery cells
More about typical machine vision applications in battery cell production
How you can increase the efficiency of your production by using machine vision

Different cell types

The main application for lithium-ion battery packs is electric mobility. Though there are three types and formats in use, the functional principle of all types is essentially the same. The main differences are in the design, requirements, and materials used.

Pouch cell

The geometry of the pouch cell is almost arbitrary and the size is easily scalable. The free positioning of the cell arresters and the electrode stacking (anode on cathode, divided by a separator) allow good heat dissipation and simple energy management.

Prismatic cell

The prismatic cell also consists of stacked anode and cathode packages. The fixed metal housing provides advantages when assembling the cells into a module. The prismatic cell combines high energy density with safety and a long lifetime.

Cylindrical cell

The cylindrical cell is a proven technology in battery manufacturing. Cylindrical cells consist of an anode and a cathode isolated by a separator and wound into a roll. The round design results in a loss of space at the battery pack module level.

Battery cell manufacturing involves four main process steps

Lithium-ion battery cell production consists of four main process steps: electrode production, cell assembly, cell finishing, and battery pack assembly. The electrode production and cell finishing process steps are largely independent of the battery cell type, while cell assembly distinguishes between pouch or prismatic cells and cylindrical cells. Regardless of the cell type, the smallest unit of any lithium-ion cell consists of two electrodes and the separator that divides them from one another. In between is the ion-conducting electrolyte.

Machine vision ensures product quality and process stability

Machine vision systems provide valuable information during the production process, including inspecting materials and ensuring process steps are correctly executed. Different solutions are available depending on your application needs. By combining our frame grabber-based systems with VisualApplets and our high-sensitivity line scan cameras, the resulting vision system can easily cope with the high speeds found in electrode production. High-resolution ace 2 X visSWIR cameras inspect the structures of separator foils inside the cell. Our area scan cameras, working in conjunction with pylon vTools, check that the cathode and anode are correctly positioned on top of each other during the winding of prismatic cells. Catching even the smallest defect is critical, since accurate error tracking increases productivity.

Where is vision used in battery cell manufacturing?

Anomaly detection

Optical anomaly detection compares the condition of materials or components to a pre-defined target condition and locates possible deviations.

Object detection and classification

Image analysis detects and categorizes defects and irregularities. This allows systems to be adjusted and provides a basis for deciding whether the material is within tolerances or must be rejected.

Measuring defects

Once defects or contaminants have been detected and localized, they can be measured. This allows conclusions to be drawn about the type and extent of the defect.

Code reading

Barcodes, QR codes, PDF417 codes, data matrix codes, or Aztec codes: materials and semi-finished products are marked with codes for tracking during process steps or for faster handling in the material flow.

Use cases in battery cell manufacturing

Machine vision helps ensure the quality of processed materials and minimizes possible material waste. Our solutions can help.

Quality assurance for stacking pouch battery cells
Precisely layering the electrode sheets and separator is critical for the quality of the battery cell. Machine vision provides accurate stacking alignment in the µm range.
Quality control in electrode coating
Coating the substrate foil with slurry is a critical production step in battery cell manufacturing. Our vision technology quickly detects particles and voids in large amounts of image data.

Most popular products

For efficient and reliable machine vision applications in this industry, the following Basler products are often the best choice:

VisualApplets
With VisualApplets the programming of FPGAs on a graphical user interface succeeds completely without hardware programming.
pylon vTools for image processing
Quickly and easily design functions like intelligent structure recognition, micrometer-precise object positioning, or robust code recognition. Flexibly integrate everything you need into your own application.
Frame grabbers
These boards provide robust, high-speed image acquisition and processing as well as signal control. The FPGA processors ensure real-time processing.
Line Scan Cameras
We offer line scan cameras with different resolutions, CMOS sensor, interfaces, and data rates - for better quality assurance and sorting processes.
Basler boost area scan camera
The Basler boost camera series combines the latest CMOS sensor technology with high bandwidths and all the other advantages of the CoaXPress 2.0 standard.
Basler ace 2 area scan camera
The ace 2 is available with various sensors and in several wavelength ranges, optionally with CoaXPress 2.0, USB 3.0, GigE, or 5GigE interface.
ace 2 X visSWIR
Basler Short Wavelength Infrared cameras offer state-of-the-art SWIR technology with your choice of resolution and USB 3.0 or GigE interface.
ace 2 X UV camera
Basler ultraviolet cameras offer state-of-the-art UV technology with USB 3.0, GigE, or 5GigE interface.

Image Processing in Battery Cell Manufacturing

Machine vision provides quality control

High performance & speed

Durable & reliable

Simple integration

Availability & reliable delivery

Different cell types

Pouch cell

Prismatic cell

Cylindrical cell

Battery cell manufacturing involves four main process steps

Machine vision ensures product quality and process stability

Where is vision used in battery cell manufacturing?

Anomaly detection

Object detection and classification

Measuring defects

Code reading

Use cases in battery cell manufacturing

Quality assurance for stacking pouch battery cells

Quality control in electrode coating

Most popular products

VisualApplets

pylon vTools for image processing

Frame grabbers

Line Scan Cameras

Basler boost area scan camera

Basler ace 2 area scan camera

ace 2 X visSWIR

ace 2 X UV camera