Battery Weld Inspection
Battery weld inspection in GoCater devices involves a thorough examination of the welded joints in the battery assembly. This process ensures the integrity and quality of the welds, preventing potential issues such as poor connections or safety hazards.
There is a growing demand for high-performance batteries, such as lithium-ion for mobile and stationary energy storage. Reliable manufacturing processes are essential during battery production as they prevent premature performance degradation or, in the worst case scenario, cell/battery explosion.
3D machine vision systems play a critical role in ensuring battery quality and minimal waste. In this feature application we’ll focus on four key phases of battery weld inspection using 3D smart sensors.
Pre-welding gap & flush measurement
Before the battery is welded, engineers need to detect the gap & flush of the battery shell and top cover. If the measurement is in excess of 0.5 mm (for gap) or 1 mm (for flush), it will be impossible to weld the shell and the top cover together.
Gocator® offers high-speed 3D laser profiling and a built-in gap & flush tool to solve this challenge. The typical system configuration involves a Gocator® 2330 multi-sensor network to achieve the required field of view.
Weld seam inspection of the battery cells
The second application comes after the laser welding of the battery cells is complete. This weld has to be verified for quality in order to detect if there are any overflows or breaks/ openings in the seam.
Networked Gocator® 3D laser profile sensors are mounted at a 45 degree angle in the Z and X axes in order to scan all four edges of the battery, while delivering the same high performance on each edge
Spot welding inspection on the connector module
After the cells are welded, connectors are spot welded to the electrodes in order to build them out in series. The connector is spot-welded to the electrodes in order to build them out in series. The spot welds need to be inspected for correct height and position.
Gocator® offers two built-in tools to solve this challenge. The first is a native height* detection tool that is based on blob analysis, and the second is a position detection tool that leverages data from all four sides of the battery for high-accuracy results.
Package weld seam quality
In the next step, cells are combined into a single package that requires welding in the corner of the shell. The corner weld seam has to be inspected in order to ensure the package is stable.
Engineers can use either Gocator® 3D line profile sensors or snapshot sensors for this application, depending on their needs. Gocator® locates the seam and produces height and intensity data, as well as accurate pass (OK) counts on compliant corner weld seams and fail (NG) counts on overflowing/broken/missing seams.
Gocator® 3D smart sensors offer a variety of built-in features and functionality designed to easily solve the specific challenges of battery weld inspection in today’s growing consumer electronics (CE) industry
Only with 3D sensing are you able to measure the following features on a battery:
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