晓悟智能
New Energy Battery Inspection
A lithium battery maker's line produced 500,000 cells per day, with surface-defect inspection long reliant on manual vis...
案例图集
项目背景
A lithium battery maker's line produced 500,000 cells per day, with surface-defect inspection long reliant on manual visual checks. Affected by fatigue and subjective judgment, the missed-defect rate was high and inspection cycle times could not match the high-speed line. ZK Robotics deployed the ZK-VS300 intelligent vision system for 100% in-line inspection of cell appearance and dimensions, enabling automatic defect identification and grading.
行业痛点
Manual visual inspection has a 3% missed-defect rate, allowing critical defects to escape and create safety risks
Inspection cycle times cannot keep pace with line speed, becoming a capacity bottleneck
Defect judgment is subjective, with inconsistent standards among inspectors
Diverse cell models and complex defect types are hard to cover with traditional rule-based algorithms
解决方案
The ZK-VS300 intelligent vision system uses AI deep-learning algorithms and 3D vision to automatically identify and grade more than ten defect classes such as surface scratches, dents, and tab misalignment. It supports few-shot rapid training and model iteration, integrates with MES for defect-data statistics and traceability, and can link to line reject mechanisms for automatic sorting of defective cells.
实施效果
Missed-defect rate dropped from 3% to below 0.1%, with inspection accuracy reaching 99.8%
Inspection speed of 0.1s/item matches the high-speed line rate
Inspection staff reduced by 70%, sharply lowering labor costs
Defect data is automatically archived, providing data support for process improvement
客户评价
"The ZK-VS300 truly automated and digitized our inspection. Missed defects are essentially eliminated, and the line runs much more smoothly."
— 某新能源电池企业 质量总监 / Quality Director, a New Energy Battery Maker