INDUSTRY

New-energy batteries

From cell to module — visual inspection for new-energy battery manufacturing.

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Cell appearance, electrodes, weld seams and module-assembly inspection.

Electrode coating defects: 50μm-level precision, 97%+ detection, 100% inline inspection at full line speed.
Tab-welding defect interception: >99% detection, cold-solder misses near zero, false calls near zero too.
Cylindrical-cell final visual inspection: 98%+ defect detection, 99%+ recognition of wrinkles, leakage and bulging.
Coverage across the full battery process: from electrode coating and tab welding to cell appearance and module assembly.

Recommended systems: 2D AI AOI · 3D AI AOI

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APPLICATION SCENARIOS

7 real-world scenarios, one at a time

Cell Appearance: Wrinkles / Leakage / Bulging

Cylindrical Cell Reflective-Shell Inspection

Appearance anomalies on cylindrical cells are directly tied to battery safety and consistency — the last visual checkpoint before shipment.

Electrode: Uneven Coating / Dark Spots / Scratches

Inline Electrode Coating Inspection

Electrode coating uniformity directly determines cell capacity consistency and safety — the most upstream quality checkpoint in battery manufacturing.

Module Assembly & Dimensions

Battery Module Weld Spot Inspection

Weld spot quality in battery module assembly is directly tied to electrical connection performance and overall safety.

Battery Module Weld Misalignment Detection (Robot Vision)

New-Energy Battery Module Weld Misalignment Detection

Weld misalignment inside a battery module can raise internal resistance, cause local overheating, or even create a safety hazard.

Separator Foreign Matter & Alignment

Separator Pinhole & Coating Defect Detection

The separator is the last physical barrier between a cell's positive and negative electrodes — even a tiny pinhole can trigger an internal short circuit.

Tab Welding & Folding

Tab Welding Quality Gate

Tab welding quality is a critical safety line for batteries — burrs or cold welds can pierce the separator and trigger thermal runaway.

Top Cap & Seal Inspection

Battery Post / Top-Cap Appearance Inspection

The surface integrity and sealing of posts and top caps directly affect battery safety — a critical checkpoint before shipment.

Case studies

New-energy battery · electrode to pack

From electrode coating and tab welding to reflective cylindrical cans and winding alignment — micron-grade AI-AOI even reads mirror-finish metal.

Scene · electrode coating

A leading EV-battery maker · electrode-coating defects

ChallengeDark spots, scratches, exposed foil and drop-off are micron-scale; low-contrast, uneven coatings defeat pure 2D imaging.

Solution3D AI-AOI fuses point clouds with deep learning for micron-grade, full-line in-line inspection.

50μmMin defect

97%+Accuracy

100%Inline 100%

Scene · tab welding

A cell plant · intercepting tab-weld defects

ChallengeTab slivers, shift and cold welds tie straight to thermal-runaway risk; 2D X-ray cannot resolve layers and escapes are costly.

SolutionAI-AOI turns the existing line into a 100% automated quality gate, reading tab-weld defects layer by layer.

>99%Detection

→0missed escapes

0Cycle loss

Scene · reflective cell surface

A battery plant · final inspection of cylindrical cells

ChallengeMirror-finish cans easily turn reflections into false defects while masking real scratches and dents.

SolutionAI-AOI with multi-light computational imaging suppresses specular glare — built for tough reflective metal.

98%+Pass accuracy

99%+Defect detection

✓Reflective

Cases are anonymised industry scenarios; the figures are typical ranges achievable with WeLinkirt DaoAI solutions.

In-depth cases · IN-DEPTH

New-energy Battery · in-depth cases

Each case breaks down the path to deployment in a real scenario — industry context, pain points, the DaoAI solution and the results.

EV battery cell production and inspection

Battery · 2026-05-27

Inline Full Inspection of Electrode Coating: 3D AI-AOI Securing Cell Consistency at the Source

A leading power-battery manufacturer deployed DaoAI 3D AI-AOI at the coating stage, fusing point cloud and image data to detect dark spots, scratches, exposed foil and material drop-off below 50μm, holding accuracy above 97% with 100% inline inspection.

DaoAI smart factory with robotic visual inspection

Battery · 2026-05-25

Tab-Welding Quality Gate: Stopping Burrs and Cold Welds Before Thermal Runaway

A cell manufacturer added a DaoAI AI-AOI automated quality gate to an existing tab-welding line, identifying burrs, misalignment and cold welds tied to thermal runaway, building 100% automated judgment toward a zero-escape goal.

Automated factory production line with machine vision

Battery · 2026-05-23

Cylindrical Cell Reflective Can-Surface Inspection: Taming Glare with Computational Imaging

A battery plant's cylindrical-cell steel cans are highly reflective with strong curvature; DaoAI's multi-light computational imaging suppresses glare, reaching judgment accuracy above 98% and defect detection above 99%.

Smart manufacturing line with AI visual inspection

Battery · 2026-05-21

Anode-Cathode Alignment in Winding and Stacking: 3D X-ray CT plus AI Layer Analysis at ~90x Speed

A leading power-battery manufacturer used DaoAI 3D X-ray CT with AI layer-by-layer analysis to replace manual reading, raising anode-cathode alignment and bend-inspection efficiency by about 90x.

AI inspection control and monitoring console

Battery · 2026-05-19

Inline Inspection of Separator Pinholes and Coating Defects: Micron-Level Control on High-Speed Web

A battery plant's separator line runs fast and wide; DaoAI's high-speed web inline AI-AOI detects pinholes, coating scratches and thickness non-uniformity, achieving micron-level inline full inspection.

FAQ

EV Battery · AI Visual Inspection FAQ

Which key battery production steps does AI vision inspect?

It covers inline electrode coating, separator pinholes, tab-welding quality, X-ray / CT electrode alignment, and reflective cylindrical-can inspection, protecting consistency and safety gates.

Coating defects are tiny and lines run fast, can AI keep up?

Yes. DaoAI models are optimized for high-speed coating, detecting exposed foil, dark spots and thickness variation in real time to match high-throughput continuous production.

How are safety-critical items like tab welding and electrode alignment gated?

DaoAI inspects tab-weld morphology with 2D vision and checks internal electrode alignment via X-ray / CT, serving as a safety gate that lowers thermal-runaway risk.

Cylindrical cans are highly reflective and prone to false judgments, what helps?

DaoAI suppresses metallic glare with feature-cognition models and optimized lighting, reliably finding scratches, dents and stains on curved cylindrical cells while reducing false calls.