SICK Quality Control Applications

in EV Battery Industry
Ryan Morris
SICK Market Product Manager – Machine Vision
 15 16 17

7 10 11
11

10
12 13 14 15

5
3 4

2 4

2 3 7 8 9

1 6

1. Material Container Inspection

1 8 Cell Roof Welding Defect Inspection
8. 15
15. Module Dimension Measurement

2. Electrode Thickness Measurement

2 9 Cell Pole Inspection
9. 16
16. Module Mounting Hole Measurement

3. Coating Edge Width Measurement

3 10
10. Cyl. Battery Placement Inspection 17
17. Foreign Object Detection

4. Hole detection
4 11
11. Pouch Cell Edge Inspection

5. High-Precision Edge Guidance

5 12
12. 3D Check of Electrode Tabs

6
6. Identifying Double Layers 13
13. Busbar Welding Inspection

7. Cell Surface Inspection

7 14
14. Cylindrical Module Flatness Check
End Products and Services in the Industry
Industry characteristics
BATTERY CELL
The battery cell can be
produced in various
chemistries and formats:
Cylindrical (hardcase) cells:
Prismatic (hardcase) cells:
Pouch cells (foil housing):
BATTERY MODULE BATTERY PACK
Battery cells are The battery pack consists
assembled to create of multiple modules, a
modules for easier cooling system and a
handling and exchange. battery management
systems.
3
Battery: Module & Pack Assembly
Application based description

Description
Battery production requires high-precision inspection
for quality control. Whether for the inspection of
housing surfaces and welding seams or the
application of heat-conducting paste, the Ruler3000
or Ranger3 3D cameras enables quick integration at
very high resolution and inspection speed.

Checking heat-conducting paste with high precision

4
3D Machine Vision Offerings from SICK

5
3D Laser Triangulation
Working principle

1. A laser line is projected on the object

2. The height profile is recorded by the camera
(angled view)*
3. By movement, multiple height profiles are
collected and results in a 3D image
*In this example a separate laser and stand-alone camera is
used to illustrate the working principle.
The Ruler3000 has built-in laser.
Feature overview Ruler3008/3020
Product | Features / Benefits

Intuitive SDK incl. GenIStream API and

SICK CMOS sensor with ROCC technology IP65/67 Stream Setup GUI
for superior image 3D performance
Easy commissioning
with guaranteed FOV
3D, reflectance and concept
scattered light
measurements in
X-resolution 63-88 µm
one device
Z-resolution 8-15 µm

Factory calibration X-resolution 25 µm ... 36 µm

shortens integration Z-resolution 3 µm ... 6 µm
time
High light sensitivity 3D profiles at up to 46 kHz
GigE Vision und GenICam in reduced ROI
allows for 3D inspection
with laser class 2 (7 kHz full frame)

7
Capture Different Materials in One Scan
Features / benefits

Objects with multiple materials like glass and metal are easy to capture in one scan due to the high dynamic range (HDR) function in
Ruler3000. HDR increases the sensor's ability to adequately reproduce both bright and dark areas in a scene. HDR is suitable for
improving the localization of the laser line when acquiring images containing both dark and bright materials, such as bright objects
towards a dark background or dark objects with bright prints.

Laser profile of bright and dark object without HDR Laser profile of bright and dark object with HDR

8
Setting New Standards for 3D Vision
Ranger3/Ruler3000

BATTERY CELL WELDING INSPECTION BATTERY CELL HOUSING INSPECTION BATTERY MODULE INSPECTION
High scanning frequency of Inspecting battery housings for defects XY measurements of module and
Ranger3/Ruler3000 enables high like scratches and dents mounting holes
scanning speed up to 46kHz

9
Material Container Inspection
Electrode mixing
1
Technical requirements:
1. Container crack and defect inspection, including inner wall and outer wall.
2. Foreign matter detection inside container, such as material residue and
particles.
3. Accuracy requirement: 0.1-0.5mm
Solution：
3D Machine Vision Camera Ruler3000 / Ranger3
Solution advantages：
1. Use special angle 15° between camera and laser, which mitigates
occlusion.
2. With 2560 X pixel and 46kHz fastest scanning frequency, SICK camera
can reach fast scanning speed, and provide high accuracy.
Customer benefits：
1. Save raw material waste cost.
2. Improve YIELD and save labor cost.
10
Cell Surface Defect Inspection
Battery cell assembly
7
Technical requirements:
• Metal surface defects or defect in insulation foil
• Height ≥ 0.1mm, X/Y Dimension＞0.5mm*0.5mm
• Protective foils are added to the module and need to be checked for holes,
scratches, dents etc.
Solution：
3D Machine Vision Camera Ruler3000 or Ranger3
Solution advantages :
1. SICK M30 chip is used for Ruler camera, which can achieve 46KHz
scanning frequency maximum.
2. Ruler3000 or Ranger3 solution can be used according to customer
requirement to scan whole surface at one time.
Customer benefits：
1. All in one camera and pre-calibrated. Easy to use.
2. Fast scanning speed helps to save cycle time and cost.
Cell Roof Welding Defect Inspection 8

Battery cell assembly

Technical Requirements:
• Welding Defects: Height ≥ 0.1mm, X/Y Dimension＞0.2mm*0.2mm
• Check the quality of cover welding:
1. Circumscribed circle diameter(10±0.5mm)
2. Inscribed circle diameter (6±0.5mm)
3. Protrusion height (≥0.4mm)
4. Depth of depression (≤0.6mm)

Solution：

3D Machine Vision Camera Ruler or Ranger3

Solution advantages ：
1. SICK M30 chip is used for Ruler camera, which can achieve 46KHz scanning
frequency maximum.
2. SICK can provide customized solution according to specific FOV, and laser/camera
geometry can be adjusted to improve performance with Ranger3.

Customer benefits：
1. All in one camera and pre-calibrated. Easy to use.
2. Fast scanning speed helps to save cycle time and cost.

Various applications displayed above

Cell Pole Inspection 9
Battery cell assembly
Technical requirements:
1. Positive and negative electrode flatness and height difference
2. Insulation film position
3. QR code reading (optional)

Solution:

3D Machine Vision Camera Ruler or Ranger3

Solution advantages:
1. The high-speed frame rate and high resolution of Ruler/Ranger3 meets
needs for height measurements
2. Image quality meets application requirements

Customer benefits:
Reduce defective rate, save cost, save manpower
Cylindrical Battery Placement Inspection 10

Formation & aging / module assembly

Technical requirements:
1. Battery placed too high/Battery tilt/Battery lie down
2. Battery placed reversed
3. Extra battery/ Missing battery

Solution：

Configurable 3D Machine Vision Camera Trispector1060

Solution advantages ：
1. SICK provides 2 solutions to customer for analysis and compare: 2D
solution and 3D solution.

Customer benefits：
1. All in one camera and pre-calibrated. Easy to use. Up to 5kHz scan
speed.
2. 3D solution is more stable than 2D solution, considering ambient light
influence

14
3D Check of Electrode Tabs 12

Module assembly

› Quality check of dimensions and bending angle of tabs

› Before the welding process of pouch cells as part of battery module
assembly, manufacturers need to ensure that the electrode tabs are
in the correct state.
› Configurable easy-to-use 3D solutions

SICK Solution: Configurable 3D Vision with

TriSpector1000

15
Pouch Cell Edge Inspection 11

Degassing and testing / module assembly

Technical requirements:
1. Pouch cell edge banding thickness measurement
2. Accuracy requirement: 3um

Solution:

1
3D Machine Vision Camera Ruler3008
2
3
4 Solution advantages ：
5 1. SICK M30 chip is used for Ruler camera, which can achieve 46KHz
6
7 scanning frequency maximum.
8
2. Ruler3008 delivers
9
10 1. Z resolution (height): 3 µm ... 6 µm, repeatability 1.6 µm
2. X resolution (width): 25 µm ... 36 µm

Customer benefits：
1. All in one camera and pre-calibrated. Easy to use.
2. Fast scanning speed helps to save cycle time and cost.

16
Battery Weld Inspection 13

Module assembly

Technical requirements:
1. Welding circle incomplete inspection
2. Lack of weld inspection
3. Welding misalignment inspection

Solution：

3D Machine Vision Camera Ruler3008

The Ruler3008 3D camera measures the shape and positioning of the welding.
3D inspection is used to check surface defects, monitor welding seams or
control dimensions.

Solution advantages ：
1. Detect incomplete and incorrectly oriented weld seams at high speeds.
2. SICK M30 chip is used in the Ruler camera, which can achieve 46KHz
scanning frequency maximum.

Customer benefits：
1. Ensure correct electrical connection of battery cells to the busbar

17
Cylindrical Module Flatness Check 14

Module assembly
Technical requirements:
1. Flatness of the upper surface of the battery, with 0.05mm accuracy.
2. Cell positive and negative pole detection.

Solution:

3D Machine Vision Camera Ruler or Ranger3

+ EasyRanger image processing

Solution advantages:
1. Actively cooperate with customers to test, and provide a variety of
solutions for customers to choose
2. EasyRanger development saving software cost.

Customer benefits:.
1. Customized set-up for customers and best fits customer needs.
Module Dimension Measurement 15

Module assembly
Technical requirements:
1. Flatness of upper surface, flatness of 4 corners. Accuracy within 0.04mm
2. Thickness of module, Accuracy within 0.04mm
3. XY measurements of module, mounting holes. Accuracy within 0.04mm.

Solution：

3D Machine Vision Camera Ruler + 2D Vision Camera

Solution advantages ：
1. Use customized angle 15° between camera and laser, which mitigates the
occlusion of corner mounting holes.
2. With 2560 X pixel and 46kHz fastest scanning frequency, SICK camera
can reach 400mm/s scanning speed, and provide high accuracy.

Customer benefits：
1. Customize camera for customer.
2. Fast scanning speed helps to save cycle time and cost.

19
Module Mounting Hole Measurement 16

Pack assembly

Technical requirements:
1. Module side mounting hole flatness measurement
2. Mounting hole position measurement

Solution：

3D Machine Vision Camera Ruler (2pcs)

Solution advantages ：
1. Use customized set-up to satisfy customer requirement, to reach the WD
as big as possible and FOV as small as possible.
2. With 2560 X pixel and 46kHz fastest scanning frequency, SICK camera
can reach 400mm/s scanning speed, and provide high accuracy.

Customer benefits：
1. Customize camera for customer.
2. Fast scanning speed helps to save cycle time and cost.

20
Foreign Object Detection System 17

When connecting the high-voltage battery (HVB) to

the car body, a foreign object such as a screw can
quickly puncture the battery cells of the HVB. This
can in turn severely damage the battery cells,
subsequently endangering people and causing
damage to the system and car parts. Before
connecting the car body and the HVB, the latter must
therefore be inspected for foreign objects: Using
laser triangulation, the foreign object detection
system (FOS) scans the HVB in an inspection cell very
quickly and with high precision.

› Detects very small foreign objects of various

shapes, e.g. screws, nuts and tools
› Reliable and accurate testing, even for challenging
surfaces with different colors, structures and
textures. Suitable for light, dark, smooth, ribbed,
calotted, glossy, matte and other surfaces
› No additional illumination required
SICK Machine Vision
Your partner for Machine Vision solutions
› Word leading 3D performance
− SICK designed CMOS 3D sensor
− Technology leap in 3D performance
› Deep Learning for Machine Vision
− Easy configurable SensorApp (SICK Nova)
− Full flexibility with SICK AppSpace
› Broad portfolio for Machine Vision
− Best fit solution and full flexibility with 2D and
3D Machine Vision
− Easy configuration, yet extendable (SICK Nova)
− Ready-to-use solutions with SensorApps
› Long time partnership for future solutions
− 30 years+ of close customer cooperation for
Machine Vision solutions in a wide range of
industries
− High Machine Vision competence close to you
with SICK Global network
22
Thank you.