Optical Inspection for safe Batteries
senswork presented its optical inspection and quality assurance solutions for battery production at the Bavarian Battery Congress 2025 in Nuremberg. The focus was on high-performance image processing systems that ensure that battery cells, modules, and packs are manufactured with precision, assembled safely, and tested reliably.
With the growing demand for high-voltage batteries, the requirements for precision, traceability, and process reliability in manufacturing are increasing. senswork offers modular testing solutions that can be flexibly integrated into existing production lines – from cell stacking and laser welding to end-of-line inspection of complete packs.
Solutions at a glance:
- Cell and module inspection: Camera-based systems check the position, orientation, and alignment of individual cells before they are installed in modules. Deviations are immediately detected and automatically compensated for – ensuring precise stack geometry and reliable electrical connections.
- Laser weld seam inspection: Specialized machine vision solutions detect weld spatter, seam misalignment, and cracks in high-current connections. Even complex copper and aluminum connections are reliably assessed – inline, with high resolution and process speed.
- Label and leak testing: OCR/OCV checks ensure that labels are correctly positioned, legible, and traceable. In addition, optical systems are used to check seals and test for leaks in battery housings.
- End-of-line inspection: Before the battery pack is finally approved, high-resolution cameras check mechanical features, screw connections, safety components, and electrical contact points. The results are automatically documented and transferred to the higher-level quality management system.
“Our goal is to identify critical quality characteristics early on in the process, thereby minimizing rejects, returns, and safety risks,” explains Andreas König, Head of Sales at senswork. “Optical inspection technology is key to stable, scalable processes, especially in battery production for electric vehicles.”
At the trade fair stand, visitors were given a practical insight into the current system generation and examples from real-world applications. There was particular interest in the intelligent combination of deep learning, 3D inspection, and automation.
Caption 2: 2D and 3D image processing and AI enable the inspection of safety-relevant components such as safety valves or bursting discs. (Image: senswork)
Caption 3: Before welding, the battery terminals are checked for contamination, precise alignment, and intact surfaces. (Image: senswork)
Caption 4: A positioning system prior to welding ensures precise spacing, accurate alignment, and good contact between the components. (Image: senswork)
Press Contact
Hedwig Unterhitzenberger
+49 8677 409958-37
hedwig.unterhitzenberger@senswork.com
senswork GmbH, Gewerbepark Lindach D 3, 84489 Burghausen