INDUSTRIES
Battery
Challenge
Many sectors, from transportation to energy, are pushing for electrification in order to transition to cleaner energy sources, reduce carbon emissions, and modernize the country's infrastructure. As more sectors adopt electric technologies, they drive demand for high-capacity, efficient, and durable batteries. This is particularly evident in the EV market, where batteries are a central component.
To meet rising demand, substantial investments are being made to expand lithium-ion battery production capacity in the US. The US government is further spurring both supply and demand by creating incentives for consumers to buy EVs and manfacturers to produce these batteries domestically.
One of the key challenges lithium ion battery manufacturers face is quality issues, as defects can cause costly recalls and present danger to end consumers. Battery manufacturers are increasingly looking to automated inspection technologies to meet production demands and ensure reliable, high-quality batteries reach their customers.
To meet rising demand, substantial investments are being made to expand lithium-ion battery production capacity in the US. The US government is further spurring both supply and demand by creating incentives for consumers to buy EVs and manfacturers to produce these batteries domestically.
One of the key challenges lithium ion battery manufacturers face is quality issues, as defects can cause costly recalls and present danger to end consumers. Battery manufacturers are increasingly looking to automated inspection technologies to meet production demands and ensure reliable, high-quality batteries reach their customers.
Introducing UnitX
UnitX provides AI vision to help manufacturers automate inspection. UnitX is currently used by 10 of the world's top 30 lithium ion battery manufactures to detect defects for all 3 battery types (prismatic, pouch, and cylindrical) and across the entire lithium ion battery manufacturing process (from electrode to cell to module to pack).
Advantages
UnitX's unique advantages ultimately help lithium ion battery manufacturers ensure quality while improving yield:
Reduced cost
100% automated inline inspection replaces need for manual inspectors
Increased throughput
High-speed imaging & AI inference speeds that match cycle times
Reduced waste
Deployable across all stages of lithium ion battery manufacturing processes to identify defects early in the production process and provide rapid corrective action
Reduced escapes and improved battery performance
Accurately detects defects that are highly variable and complex in shape, size, and presentation
Reduced overkill
Adjustable thresholds to distinguish unacceptable defects from defects that are within tolerances and still functional
Faster deployment
Sample-efficient AI that requires as few as 5 images to train
Reduced cost
100% automated inline inspection replaces need for manual inspectors
Increased throughput
High-speed imaging & AI inference speeds that match cycle times
Reduced waste
Deployable across all stages of lithium ion battery manufacturing processes to identify defects early in the production process and provide rapid corrective action
Reduced escapes and improved battery performance
Accurately detects defects that are highly variable and complex in shape, size, and presentation
Reduced overkill
Adjustable thresholds to distinguish unacceptable defects from defects that are within tolerances and still functional
Faster deployment
Sample-efficient AI that requires as few as 5 images to train
Applications
UnitX automates inspection across all lithium ion battery manufacturing processes such as:
Electrode Manufacturing
In the electrode manufacturing process, electrode material is mixed, coated onto metal foils, dried out, and shaped into individual electrodes.
UnitX inspects electrodes for dimensional uniformity and defects that degrade performance and compromise battery safety. By inspecting electrodes at this stage, UnitX helps manufacturers reduce wasted resources downstream. Manufacturers can use UnitX configurable threshold capabilities to distinguish defects that are within acceptable tolerances from functional defects.
Electrode Manufacturing
In the electrode manufacturing process, electrode material is mixed, coated onto metal foils, dried out, and shaped into individual electrodes.
UnitX inspects electrodes for dimensional uniformity and defects that degrade performance and compromise battery safety. By inspecting electrodes at this stage, UnitX helps manufacturers reduce wasted resources downstream. Manufacturers can use UnitX configurable threshold capabilities to distinguish defects that are within acceptable tolerances from functional defects.
Cell Assembly
Next is the cell assembly stage. In this stage, separator, anode, and cathode electrodes are layered, welded together, and filled with electrolyte.
UnitX detects cell assembly defects that can impact battery functionality, performance, and safety-- even causing electrical shortages and fires.
Next is the cell assembly stage. In this stage, separator, anode, and cathode electrodes are layered, welded together, and filled with electrolyte.
UnitX detects cell assembly defects that can impact battery functionality, performance, and safety-- even causing electrical shortages and fires.
Cell Finishing
After battery cells are filled with electrolyte, they undergo finishing processes such as sealing, formation, and aging processes that serve to stabilize and optimize the battery. This is the final opportunity to inspect a cell before it's integrated into a module, so manufacturers conduct rigorous performance and quality testing called "end-of-line" battery cell inspections.
UnitX inspects finished battery cells to detect defects that can compromise battery performance, reliability, and safety.
After battery cells are filled with electrolyte, they undergo finishing processes such as sealing, formation, and aging processes that serve to stabilize and optimize the battery. This is the final opportunity to inspect a cell before it's integrated into a module, so manufacturers conduct rigorous performance and quality testing called "end-of-line" battery cell inspections.
UnitX inspects finished battery cells to detect defects that can compromise battery performance, reliability, and safety.
Module Assembly
Individual battery cells are then combined into larger modules with greater electrical voltage and capacity. This process takes individual lithium-ion cells and assembles them into a functional unit with proper electrical connections, monitoring systems, and protective housing. The result is a safe and functional unit that makes up the battery packs that power EVs and other applications requiring large amounts of stored energy.
UnitX inspects battery modules to verify the correct positioning of cells within the module, the quality and integrity of the welded connections, the correct integration of additional components such as the thermal management system and BMS, and the integrity of the protective casing. This ensures module reliability, safety, and compliance with specifications.
Individual battery cells are then combined into larger modules with greater electrical voltage and capacity. This process takes individual lithium-ion cells and assembles them into a functional unit with proper electrical connections, monitoring systems, and protective housing. The result is a safe and functional unit that makes up the battery packs that power EVs and other applications requiring large amounts of stored energy.
UnitX inspects battery modules to verify the correct positioning of cells within the module, the quality and integrity of the welded connections, the correct integration of additional components such as the thermal management system and BMS, and the integrity of the protective casing. This ensures module reliability, safety, and compliance with specifications.
Applications:
Pack Assembly
Pack assembly is the final battery manufacturing process where battery modules and components are assembled into a battery pack with greater electrical voltage and capacity. This process takes battery modules, connects them electrically, adds thermal management, and houses them all together into a functional unit for safe and functional use within EVs and other applications requiring large amounts of energy.
UnitX inspects battery packs to verify the correct positioning of modules within the pack, the quality and integrity of the welded connections, the correct integration of additional components such as the thermal management system and BMS, and the integrity of the protective casing. This ensures pack reliability, safety, and compliance with specifications.
Pack assembly is the final battery manufacturing process where battery modules and components are assembled into a battery pack with greater electrical voltage and capacity. This process takes battery modules, connects them electrically, adds thermal management, and houses them all together into a functional unit for safe and functional use within EVs and other applications requiring large amounts of energy.
UnitX inspects battery packs to verify the correct positioning of modules within the pack, the quality and integrity of the welded connections, the correct integration of additional components such as the thermal management system and BMS, and the integrity of the protective casing. This ensures pack reliability, safety, and compliance with specifications.
Applications:
Solutions
AI Only(via integration with third party vision systems)Rapid deployment of UnitX AI with existing systems. UnitX's CorteX integrates with traditional third party vision systems to provide defect detection faster and more accurately where you already have vision systems deployed- AI Only(via integration with X-Ray / CT Scanners)Rapid deployment of UnitX AI with existing systems. UnitX's CorteX integrates with X-Ray / CT scanners to more accurately detect internal defects not apparent on the surface such as internal battery structural defects
Imaging + AIBest-in-class inspection using UnitX imaging and AI. UnitX's OptiX dynamically illuminates parts while UnitX's CorteX detects variable defects across the entire lithium ion battery manufacturing process
Battery Application Examples
To learn more about how UnitX can automate inspection for you, please contact us here