Multi-sensor system for quality inspection of battery cells
The precise inspection of sensitive battery cells places the highest demands on handling and measurement technology. An intelligent multi-sensor system enables reliable defect detection as well as highly accurate geometric measurement, thereby ensuring quality throughout the entire inspection process.
We developed a modular solution for robot-assisted inspection of different battery types. Reliable process handling and seamless quality control play a decisive role in modern manufacturing, as even the smallest mechanical loads or defects can impair the function and safety of the battery cells. The objective was therefore to create a flexible solution that combines precise positioning with detailed surface and geometry inspection.
For implementation, a robot is used to automatically feed the battery cells to various inspection stations. First, a high-resolution 3D structured-light camera performs precise position detection of the components and enables gentle, millimetre-accurate gripping. After safe removal, detailed surface inspection is carried out using photometric stereo technology. By combining multiple lighting angles, a high-resolution 2.5D image is generated that makes even the smallest defects such as scratches, dents or inclusions visible and enables reliable classification.
In a further inspection step, the battery surface is measured. The generated point cloud is used to precisely analyse flatness as well as the smallest geometric deviations. In this way, it is ensured that only flawless components proceed to downstream processes.
What makes this solution special is the intelligent combination of different camera technologies within a single system. Through the seamless integration of 3D image processing, photometric stereo and precise sensor data processing, a highly flexible and scalable inspection environment is created. This enables continuous adaptation to different component geometries and increasing quality requirements.
The growing need for precision, process reliability and documented quality in battery production was the key driver behind the development of this demonstrator. The solution shows how the targeted use of modern sensor technologies can deliver reliable and future-proof quality inspection.
Success Story
We don’t have customers, we have partners
I was particularly impressed by the fact that the competent and motivated staff always responded to interim changes to the plan in a friendly, quick, and flexible manner, and that our requested changes were implemented at no additional cost
ID has excellent, motivated, and friendly specialists in manufacturing process automation who know exactly what they're doing. From conception to production, all the experts are in-house, which made working with us much easier.
We supply high-quality components for industrial image processing, which ID uses in special-purpose machine construction. In addition, ID conducts professional training courses for our software at customers' sites, which significantly contributes to the efficient use of the components in automation.
