In the era of lithium-ion TWh, the production goals of higher efficiency, energy conservation, and safety pose a new challenge for lithium-ion manufacturing enterprises. As a key link in empowering quality intelligent manufacturing, machine vision is rapidly developing, and more and more players are entering the track.
The Huahan Weiye machine vision system is widely used in the entire process of lithium batteries, achieving full coverage. By delving into various process stages such as core electrode fabrication, battery cell assembly, and battery packaging, we have a deep understanding of the testing issues in the lithium battery industry, achieving rapid response and evaluation, greatly shortening the project implementation cycle, and truly achieving quality improvement, cost reduction, and efficiency enhancement.
Lithium ion battery module PACK is usually composed of multiple cells (monomers) and connected to each other through cables or board connectors. Each battery cell contains components such as a positive electrode, negative electrode, separator, and electrolyte. After the assembly of the battery cells is completed, they are connected in series through plate connectors or cables to form a module, then fixed with insulation tape or other materials, and finally connected to other modules or external equipment.
The lithium battery module PACK is the core of the vehicle energy storage system, which directly affects the performance and range of the vehicle. Huahan Weiye has developed a comprehensive inspection plan for power modules and has now implemented multiple battery module projects.
Busbar welding is an important part of the assembly process of power battery module lines. To ensure welding quality and prevent problems such as low welding efficiency and safety caused by position deviation and low positioning accuracy, it is necessary to perform positioning and addressing before welding to control the gap between the paddle and the pole.
Huahan Weiye adopts the InnoVision 2D detection system, which can accurately locate the positions of Mark points and pole columns through grayscale matching tools. Through secondary positioning of Mrak points, accurate pole position data is provided for laser welding, which can be batch tested, with fast shipping speed and high accuracy.
In the process flow of the module pack section, Busbar welding connects different battery cells in series and parallel through connecting paddles. To ensure welding quality, the gap between the paddles and the pole column needs to be controlled before welding, and the appearance of the weld seam needs to be inspected after welding to prevent welding defects from entering the process.
The traditional 2D detection imaging effect fluctuates greatly, resulting in high reflection in the image and inability to accurately extract the contour of the weld seam. Therefore, in response to the above problems, Huahan Weiye has added 3D high-precision visual inspection technology to the visual inspection scheme, which can perform pre weld and post weld appearance inspection on the module Busbar to ensure the quality of the module.
The Huahan Weiye HyperShape 3D detection software delineates the detection area by adding detection tools, flexibly sets parameters such as upper and lower height thresholds and welding smoothness, and then compares the height and welding smoothness information of each location within the area to easily complete OK/NG judgment. Realize dynamic repeatability of 0.02mm for pre weld gap detection, and measurement accuracy of 0.1mm for post weld seam length and width, with fast speed and high accuracy. It can stably detect defects such as explosion points, dents, protrusions, weld penetration, cracks in welds, etc., with a missed kill rate of 0% and a misjudgment rate of<0.1%.
At present, most of the detection in the industry is based on 2D images, which can only detect the length and width of the weld seam. The height of the weld seam cannot be detected. At the same time, due to the smooth surface of the side weld seam of the module, it is easy to produce reflection, which affects the imaging quality of the weld seam, making it easy to have inaccurate or misjudged weld seam positioning during detection.
The Huahan Weiye HyperShape 3D detection software uses cross-sectional contour analysis tools to effectively detect the height, area, and distance from the positioning point of the weld seam contour. It analyzes the concavity and convexity, detects defects such as explosion points, pits, and splashes, and achieves a missed judgment rate of 0% and a misjudgment rate of ≤ 0.5%.
Due to external factors that may cause bulging during the use or production of batteries, it is necessary to perform flatness testing on the bottom surface of all battery cells after template assembly, as well as coplanarity testing on the four fixed angle support end plates, to prevent subsequent installation defects.
Huahan Weiye uses HyperShape 3D detection software to measure the flatness of the module bottom surface and the coplanarity of the end plate using the least squares method. It can achieve dynamic repeatability accuracy of 0.02mm, measurement accuracy of 0.03mm, high accuracy, and a missed detection rate of 0%.
Huahan Weiye's overall solution for the lithium battery industry, with its advantages of wide application areas, flexible solutions, and higher deployment efficiency, has been successfully applied in various processes of lithium battery production, helping enterprises improve the consistency, yield rate, and safety of lithium battery production.
With the widespread application of machine vision in the lithium battery industry, Huahan Weiye will continue to provide the best products and services for lithium battery equipment manufacturing enterprises and end partners, solve various problems and challenges faced on the production line, and efficiently assist in the intelligent development of the lithium battery industry.
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E-mail：Marketing@hhwytech.com
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