Industry Lithium Battery

Overview

One-stop, high-speed, and high-precision cylindrical cells inspection

The Hybrid Data Camera deployed on a production line for rapid and robust quality control of cylindrical battery cells.

Alt-text: Production line scene showing Hybrid Data Camera inspecting cylindrical battery top surfaces.

In battery manufacturing, defect detection is central to ensuring product quality. For cylindrical batteries, the cell top surface is a vital part because it directly affects the performance and safety of lithium-ion batteries. Surface warpage, dents, bumps, and scratches… These minor manufacturing defects may lead to major problems in the downstream assembly step, such as poor internal contact, abnormal increases in internal resistance, and shortened cycle life.

A better solution lies with a high-precision and intelligent inspection method, which effectively helps identify and exclude cylindrical cells with functional defects, ensuring stable performance and long-term reliability of power battery products.

This article shares how Mega Phase Technology's Hybrid Data Camera enables high-precision inspection of cylindrical battery top surfaces within a second.

Compact Integration: The simplified setup featuring the Hybrid Data Camera DM081 and Programmable Screen Light, replacing complex multi-station systems.

Alt-text: Installation diagram of Hybrid Data Camera and lighting for battery top end inspection.

Project requirements

Detect surface defects such as bumps, dents, hard/soft scratches, contamination, and impurities on the cell top with confidence.

FOV: 110 mm x 70 mm

Model

Hybrid Data Camera DM 081

Lens: MPD-F2518M-G

Programmable Screen Light Kit: MPD-SL-17

Output images of defects and flaws

Our best-fit camera reliably captures defects and flaws and some results are posted as follows:

Dents-2.5D image

Scratches-2.5D image

Scratches-2.5D image

Scratches-2.5D image

Technical advantages

Top Speed - 540ms full cycle time

With Mega Phase’s advanced HWCI technology*, the camera completes a full inspection cycle in only 540 ms and outputs seven computed images from respective channels in a single shot. This enables clear identification of bumps, dents, scratches, contamination, water stains, and other surface defects.

On this website, HWCI stands for Hardware Computational Imaging, our proprietary hardware acceleration technology powered by FPGA-based parallel architecture. It enables all industrial cameras manufactured by Mega Phase to capture, compute, and transmit just within the hardware and at a higher speed. With task-level parallelism, industrial cameras with HWCI excel at inline measurements and inspections, as they free substantial IPC resources for further development and a lot of time for high-throughput production lines.

Higher integration, budget-friendly system

One Hybrid Data Camera system replaces multiple inspection stations and eliminates the need for traditional 2D lighting systems. Therefore, it is easier (for system integrators and machine makers) to deploy, replicate, and port to various industrial applications, achieving lower system cost and higher efficiency.

In this setup, a single Hybrid Data Camera can cover 12 cylindrical top ends at once. It is also able to handle different products and detect multiple types of defects by simply switching lens and lighting combinations. This makes it easy to adapt the same setup to various inspection tasks and application scenarios.

A more flexible system

Driven by Industry 4.0 and the rise of smart manufacturing, defect detection for lithium-ion cylindrical cells is rapidly moving toward smarter and more integrated solutions. At Mega Phase Technology, we utilize our high-precision visual inspection products, including the 2.5D Hybrid Data Camera, to enhance battery manufacturing by advancing quality and reliability. We are here to safeguard every journey.

Contact us now for more success stories!