INDUSTRY

EV Battery

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

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

  • Feedback from real lines and real scenes can't be bought.

  • Eight years on the floor, line by line — hard-won engineering experience.

  • Full-stack in-house — the whole chain from sensor to world model is ours.

  • 100M+ real industrial data points continuously refine one world model.

Key checks · KEY CHECKS

Electrodes: uneven coating / dark spots / scratchesTab welding & foldingCell surface: wrinkles / leakage / swellingSeparator contaminants & alignmentModule assembly & dimensionsTop-cap & seal inspection

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

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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
→0Escapes
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.

Read more 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.

Read more 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%.

Read more 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.

Read more 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.

Read more

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.