Case Study | A Leading Battery Manufacturer Improves Cell Winding Quality with LineX Macro Cameras
INSNEX developed a compact macro vision inspection system for a leading lithium battery manufacturer to address limited space, high operating speeds, complex electrode defects and demanding accuracy requirements in cell winding. Four sets of high-precision CIS cameras +AI algorithms inspect both sides of cathode and anode sheets simultaneously. Dynamic compensation and subpixel image processing deliver a defect detection rate of ≥99.8% and a false detection rate of ≤0.1% at 150m/min, with ceramic coating misalignment measurement of ±0.05mm precision. Easy installation in confined spaces, rapid adaptation and MES data integration help increase daily throughput by 40% and reduce manual sampling workload by 80%, improving winding inspection efficiency and product quality.
01 Introduction
Against the background of the rapid development of the new energy industry, a lithium battery leading customer introduced the INSNEX compact macro vision inspection system to stably achieve 150 meter/minute high-speed inspection through four sets of high-precision CIS cameras and AI algorithm. Camera resolution of this system: 14um/28um/42um optional; defect detection rate: zero missed defects, false rejection <0.2 %.
02 Challenge
In the complex production process of lithium batteries, one of the key process stages is winding. The winding machine drives the winding needle to wind the positive and negative electrode sheets and separators in a specific order, thereby forming a battery core, which is the smallest unit of the power battery of new energy vehicles. At the same time, various problems such as electrode sheet flaws, irregular winding, and electrode sheets exceeding the separator will occur during the winding process, which brings considerable problems to visual inspection. Conventional wire scanning solutions and sensor solutions are far from meeting the detection requirements of flaws in the winding process.
Faced with difficult testing problems, the lithium battery customer tried a variety of solutions, looking for an online detection system for electrode sheet flaws that could be installed in the narrow space of the winding machine to improve product quality and quality, but he has never found a suitable solution. At the same time, we hope to use the latest AI algorithm to automatically classify and grade defects to ensure that the stable detection rate of defects is ≥ 99.8 %.
03 Solutions
Based on the accumulated experience of past successful projects, INSNEX worked closely with the lithium battery leading customer engineering team to propose a compact macro vision system solution in response to the problem of electrode sheet flaw detection in the narrow space of the winding machine. Through four sets of high-precision and small-space CIS cameras, synchronous detection of the front and back of cathode and anode cells is realized. Dynamic compensation algorithms and sub-pixel image processing technology are innovatively used. In the high-speed production of 150 meters/minute, the defect detection rate ≥ 99.8% and the error detection rate ≤0.1% are successfully achieved, and high-precision measurement of ceramic coating misalignment ± 0.05mm is supported. The system adopts modular design, which can be quickly adapted to different winding machine types, and realizes closed-loop management of the entire production process through MES data interaction.
04 Customer Benefit
1. Under the conditions of limited space for the winder equipment and small space occupied by the macro camera, close to the end of the winding needle to realize online synchronous detection of the front and back sides of the anode and cathode;
2. Reduce defect rates, improve product quality, and achieve "0 missed defects";
3. The daily processing capacity of a single equipment is increased by 40%, and the manual sampling workload of 80% is reduced.
05 Customer Reviews
"INSNEX's macro electrode sheet flaw detection solves the 100% detection problem before the winding needle is rolled into the winding machine, allowing us to demonstrate high-standard battery quality inspection technology to the final car companies. Moreover, INSNEX's macro camera is easy to install and simple to debug, making it very suitable for installing detection systems in small spaces, reducing the time and cost of individual shutdown and upgrading. With its excellent technology and efficient services, INSNEX has truly helped us improve our product competitiveness."
--A lithium battery leading customer quality engineer
06 About Us
INSNEX was established in 2017. It has long been deeply involved in visual inspection scenarios. Relying on its profound industry application accumulation, it has continuously explored and iterated advanced imaging products that [make defects clearer] and the "Vision+AI" platform software to continuously explore technologies and products with better experience in the field of defect detection. LineX series near field line scan cameras (NFL) are All-In-One imaging solutions built by INSNEX for compact spaces. The LineX camera has the advantages of high integration, small size, and extremely low distortion, which solves the problem of multi-machine splicing and makes clear imaging easier. Coupled with InsWorks, another "Vision+AI" platform software product from INSNEX, it can easily cope with the development and deployment of complex inspection systems and comprehensively improve the accuracy and stability of defect detection.
At present, INSNEX products have been widely deployed in industrial fields such as lithium batteries, printing, PCB, semiconductors, 3D printing. Agents cover multiple regions around the world and gather a group of senior technical partner resources to provide localized services to customers in various regions, making line-scan imaging and defect detection systems within easy reach.
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