1. Industry Pain Points
As power battery modules grow in dimension, lithium‑ion battery cover plates (busbar covers) can reach up to 2.6 meters in length. Conventional area‑scan cameras cannot cover the full field‑of‑view in one shot and require multiple image stitching. Workpieces combine highly‑reflective metal surfaces, black plastic, weld spots, aluminum busbars and connector pins. No single lighting solution can meet all inspection requirements. Manual visual inspection suffers from low efficiency and inconsistent results, and fails to satisfy MES full‑process traceability requirements of factories.
To meet customer production requirements, CKVision has completed the custom implementation of this large‑size offline AOI inspection equipment for lithium‑ion battery cover plates. It performs full pre‑delivery inspection for 2600mm×800mm battery cover plates and connector assemblies. Built on CKVisionBuilder no‑code machine‑vision software, it adopts an integrated vision‑and‑motion‑control platform. Five vision stations, direct‑drive motion axes and flip‑plate mechanisms are integrated in one system. Image acquisition, defect judgment, motion positioning, signal interlock and MES data upload are completed within one software project. The equipment has been put into production.
2. Offline AOI Inspection Equipment for Lithium‑ion Battery Cover Plates
The system adopts an offline workflow: manual loading, automatic scanning inspection and result upload to MES. Processing time per FOV is less than 1 second.
| Station | Configuration | Inspection Items |
|---|---|---|
| Top‑side line‑scan | CK‑L840CI‑42GS, coaxial light | Laser welds (missing, extra, blue/yellow/black discoloration, burst weld, position tolerance), surface foreign objects, busbar appearance |
| Bottom‑side line‑scan | CK‑L840CI‑42GS, coaxial light | Same inspection items for the bottom surface |
| Through‑beam point laser | CK‑XS060 point laser | Busbar presence & height, support up to 4 busbar rows |
| Rotating connector | CK‑S2000MI‑6RS, blue coaxial light | Rotating connector male‑pin inspection |
| Side connector | CK‑S2000MI‑6RS, dual‑RGB bar lights | Male‑pin inspection for multiple side connectors |
Key Parameters
- Imaging accuracy: Each line‑scan camera covers 282 mm; three cameras jointly cover 800 mm width at 0.035 mm/pixel.
- Motion control: Direct‑drive motor drives the scanning gantry for follow‑up scanning. Three reserved flip‑plate mounting positions support workpiece flipping for customer‑side inspection.
3. Software Platform: CKVision Integrated Vision & Motion‑Control
Traditionally, vision inspection and motion control are supplied by separate vendors, resulting in long on‑site integration cycles and ambiguous responsibility boundaries. CKVisionBuilder unifies vision algorithms and motion‑control logic in one engineering project. Projects are built via drag‑and‑drop node editing, which is the core advantage enabling fast deployment of large‑format multi‑station inspection equipment.
Business Modules
- Vision inspection tasks: Top‑ and bottom‑surface line‑scan image acquisition, point‑laser height measurement, rotating‑connector imaging, side‑connector cross‑slide imaging; defect judgment for welds, hot rivets, aluminum busbars and connectors.
- Motion‑control tasks: Direct‑drive gantry follow‑up scanning, 800 mm Y‑axis cross‑slide for point‑by‑point side‑connector inspection, axis homing, parallel movement, flip‑plate workflow, I/O interlock with host‑machine start‑stop signals.
Built‑in Motion Tools in CKVisionBuilder (No Additional PLC Programming Required)
- Axis homing tool: All axes home automatically upon startup to establish coordinate reference.
- Single‑axis / parallel‑axis movement tool: The scanning gantry travels along the workpiece length; the Y‑axis moves the camera to each connector photographing position.
- Axis‑parameter configuration tool: Visually configure direct‑drive motor parameters including speed, acceleration and hardware limits.
- I/O input & output tool: Photoelectric sensor triggers image capture upon workpiece arrival; NG signal outputs for machine‑tool alarm and rejection.
- Conditional motion‑jump workflow: Automatically switch to corresponding inspection branches at different inspection positions, realizing the logic of “move‑capture‑judge”.
- Flip‑plate mechanism interlock: Three reserved flip‑plate signal channels. After workpiece flipping, the software automatically switches to the bottom‑surface inspection workflow. Both sides can be inspected within one loading cycle.
4. Why Customers Choose CKVision
- Turn‑key delivery: One‑stop responsibility covering solution design, optical component selection, mechanical & electrical control, vision software development and on‑site commissioning; customers only need to raise functional requirements.
- One unified software platform: Image preprocessing (denoising, filtering, contrast enhancement, binarization, median filtering), pattern matching, measurement, character / barcode reading, color discrimination, presence‑absence judgment, as well as motion positioning and I/O interlock are integrated in one workflow.
- Multi‑task parallel processing: Support up to 16 simultaneous camera streams; top‑bottom line‑scan and connector imaging run without mutual blocking.
- Open communication interfaces: TCP/IP, RS232 and I/O connect directly to MES; inspection images are automatically archived and results uploaded.
- Rapid deployment for custom projects: Complete set of drag‑and‑drop workflow components including branch, jump, loop and condition judgment. Product change‑over only requires adjustment of workflow nodes and algorithm parameters.
5. About CKVision
CK Machine Vision Technology Co.,Ltd. is a national high‑tech enterprise. Since 2002, we have focused on R&D of machine‑vision algorithms. Our offerings include machine‑vision software SDK, light sources, industrial cameras, lenses and image processors. We deliver turn‑key custom AOI and vision‑inspection systems built upon our self‑developed integrated vision‑motion‑control software. We do not sell off‑the‑shelf standard machines; we deliver custom‑tailored solutions matching customer‑specific production processes.
Customers from new‑energy battery, auto‑parts, 3C‑electronics and other industries are welcome to contact us for free sample evaluation.
Website: https://en.ckvision.net
Tel: +86‑755‑33938281
Email: info@ckvision.net