3D Position Detection and Inspection of EV Battery Cells before Welding

Challenge

In EV battery production, even minimal deviations in cell spacing or alignment can compromise weld quality and long-term electrical reliability. Before the welding stage, every prismatic and cylindrical cell must be positioned with high precision to ensure proper contact between terminals and busbars. Inaccurate geometry or uneven flatness can result in weak weld seams, increased mechanical stress, and potential electrical failures.

Application and Solution                                           

senswork integrated a 3D inspection and metrology system into the assembly line to ensure reliable welding preparation.
The system automatically detects the position and orientation of all battery cells, measuring their spacing, alignment, and surface geometry in real time. This guarantees that every component is perfectly placed before the welding process begins.

Beyond position detection, the system performs a full 3D inspection of prismatic and round cells, verifying geometry, fit, flatness, and overall alignment. By combining precise optical metrology with automated control, it supports an error-free welding process and consistent module quality.

Benefits

• High welding quality through exact cell alignment
• Reduced electrical failures thanks to proper contact and geometry verification
• Lower mechanical stress on cells and connections
• Efficient assembly through automated position determination
• Reliable and safe battery modules with clean, stable weld seams

To learn more about machine vision in the E-Mobility industry, click here.