Industrie | E-Mobility

The production of lithium-ion batteries is a complex and sensitive process that requires considerable material and energy costs. This makes an efficient and precise production process all the more important. As an experienced partner in the field of e-mobility, senswork provides customized solutions for quality assurance and automation in battery production. Our advanced systems ensure process reliability and precision - from cell production to final battery testing. With our technologies, we ensure that your production processes are always optimized for maximum performance and reliability.

Metrology for E-Mobility

The future of manufacturing: machine vision for electric motors

As the central components for the electromobility of vehicles, e-motors are the focus of the automotive industry. Machine vision plays a decisive role in fulfilling the quality requirements.

With machine vision, for example, electrostatics, battery casings or battery contacts can be precisely measured. In addition, processes such as the laser welding of hairpins or busbars can be monitored using senswork systems. In doing so, it improves product quality, reduces rejection rates, increases customer satisfaction and, at the same time, promotes electric mobility.

What E-mobility Processes Do We Cover?

Optical testing and measurement technology along the battery cell production process chain

Process monitoring during laser welding of hairpins
3D inline measurement of busbars to ensure electrical connections in battery systems
3D measurement of stators
Planarity measurement of single cells and complete cell clusters
Distance measurement of single cells and battery modules
3D inspection for collision-free battery assembly
3D measurement of battery clusters to housings
3D measurement of battery housings
3D measurement of battery contacts
Automated control of the foaming of battery storage

Monitoring the laser welding of hairpins.

Electrostator

When electric motors are assembled, around 160 to 220 hairpins are welded together. With senswork's AI-based inspection system, high-resolution data from the welding points are recorded and evaluated. This is how laser welding can be automated and process quality guaranteed.

Inline measurement technology along the process chain

3D Measurement

senswork offers solutions for the entire battery cell production process. With our optical 3D measuring systems, we can measure products in real time without contact and compare them against CAD, for example, the 3D measurement of battery clusters to enclosures, battery casings and contacts.

3D CAD comparison for busbars

Busbars

senswork's 3D measuring system records the geometry of busbars in just a few seconds. Deviations in shape can automatically be detected by comparing the nominal and actual surface profiles. Correction parameters for feed and bending angle per segment are continuously and automatically determined.

Quality control when foaming battery cells

Foam

senswork has developed a process for 3D scanning of foam surfaces between battery cells. Deformations such as cavities or foam protrusion are quickly and reliably detected. This ensures that the battery foam can optimally fulfill its safety-critical function.