Case Study: Washtray Inspection in Battery Casing Production 

Overview

In the production of electric car batteries, quality assurance is critical to ensure safety and efficiency. A significant part of this process involves the inspection of washtrays that hold battery casings. The inspection ensures that the holders are free from fractures and that no battery casings remain after cleaning. To address these needs, we implemented a camera-based inspection system capable of detecting potential damage and unremoved components, supporting the fully automatic reassembly process.

Application and Solution

Electric vehicle battery production is a high-volume operation, with enormous quantities of battery casings being processed daily. Given the need for rapid throughput and precision, our camera inspection system was integrated to inspect the washtrays. This system ensures that the battery casing holders are free of any fractures and that no battery casings have been left behind.

The inspection system operates at a speed of 10 frames per second, providing high precision and reliability for identifying potential issues. A mirror system is used to achieve the best possible perspective, allowing the cameras to detect defects or unremoved components from multiple angles.

Tasks

Fracture Detection: The system identifies any structural damage, such as cracks or fractures, in the washtrays that could compromise the safety and quality of the battery casings during the reassembly process.
Component Freedom Check: It verifies that all battery casings have been removed from the holders, ensuring that no leftover components disrupt the subsequent reassembly.
Benefits

High Throughput: With a processing rate of 10 frames per second, the system keeps up with the high production demands, inspecting large quantities of washtrays without causing bottlenecks.
Optimal Inspection Perspective: The use of a mirror system provides an advantageous view, enabling the cameras to thoroughly inspect all critical areas of the washtrays for damage and leftover components.
Enhanced Reliability: The automated inspection system delivers consistent results, minimizing the risk of human error and ensuring high-quality standards are maintained throughout the production process.

Benefits

• High Throughput: With a processing rate of 10 frames per second, the system keeps up with the high production demands, inspecting large quantities of washtrays without causing bottlenecks.
• Optimal Inspection Perspective: The use of a mirror system provides an advantageous view, enabling the cameras to thoroughly inspect all critical areas of the washtrays for damage and leftover components.
• Enhanced Reliability: The automated inspection system delivers consistent results, minimizing the risk of human error and ensuring high-quality standards are maintained throughout the production process.

Outcome

Integrating this camera inspection solution into the battery casing production line has significantly improved the quality control process. By ensuring washtrays are free from fractures and unremoved components, the system supports a smooth and fully automated reassembly process. This not only enhances safety and quality but also helps to maintain the high efficiency required for large-scale electric vehicle battery production.