Vision AI for Battery Production
The mobility transition requires safe, powerful batteries - and efficient production processes. At the Tech Days 2025 in Munich (July 16–17), senswork will present a groundbreaking solution for quality assurance in battery production: an AI-supported image processing system for fully automated testing of prismatic battery cells.
The battery production industry for electric vehicles is subject to the highest quality requirements: even the smallest defects can have serious consequences for the performance, safety, or service life of a battery. senswork meets these challenges with customized testing systems along the entire value chain - from cell inspection to the finished battery storage system.
More safety, less waste
With its system, senswork demonstrates how safety and cost-effectiveness can be combined in battery production. Thanks to artificial intelligence, the manufacturer is taking optical inspection to a new level: the AI-based image processing software Neuralyze® also detects hard-to-see defects such as fine scratches or structural irregularities - in real time and at high cycle rates.
The test system presented can be used in particular for the following test tasks:
- Inspection of safety valve and bursting disc
Using 2D image processing and AI, safety elements such as the bursting disc are checked for defects or anomalies – a key contribution to ensuring pressure relief protection for each individual cell. - Surface inspection of battery terminals
ZScan® Easy uses Neuralyze® to detect the finest cracks, scratches, or particles on the contact surface. A clean pole surface is essential for the subsequent welding process (pre-weld inspection). - 3D measurement of cell and individual pole positions for the subsequent welding process
Precise measurement of the flatness and position of the battery terminals ensures stable welded joints - and thus the electrical and mechanical perfection of the entire unit.
Added value for battery manufacturers
The complete solution from senswork can be used flexibly for individual cells, modules, packs, or even entire battery storage systems. Thanks to a line scan camera, the system achieves a particularly wide field of view – with extremely high resolution and a compact design. Neuralyze® also enables long-term storage of large amounts of data, for example for seamless traceability of safety-critical characteristics.
Multi-level security
“Our system helps to make both production and the end product, the battery, safer,” explains Markus Schatzl, Head of the senswork Innovation Lab. “Intelligent image processing enables us to detect potential hazards such as scratches, defective bursting discs, damage, and contamination before they become safety issues.”
Experience it live at Tech Days 2025
Visitors to Tech Days can see the solution's performance for themselves at the senswork booth. A complete test sequence on prismatic battery cells will be demonstrated - fast, precise, and fully automated.
Caption 1: AI-based image processing in action: senswork demonstrates automatic quality inspection of EV battery modules with Neuralyze® at Tech Days 2025. (Image: senswork)
Caption 2: The AI-based image processing software Neuralyze® detects hard-to-see defects such as fine scratches or structural irregularities – in real time and at high cycle rates. (Image: senswork)
Press Contact
Hedwig Unterhitzenberger
+49 8677 409958-37
hedwig.unterhitzenberger@senswork.com
senswork GmbH, Gewerbepark Lindach D 3, 84489 Burghausen