New Energy Pouch Material AI Visual Inspection Equipment
New energy pouch materials AI visual inspection equipment: for pouch materials such as lithium battery insulation sheets, Mylar, PI film, PET film, fish paper and Nomex, it inspects holes, scratches, uneven coating, foreign matter and dimensional defects, and outputs OK/NG.
Products Overview
Holes and burrs on insulating materials are a direct risk to battery safety
New energy pouch material AI visual inspection equipment is used for inline inspection of pouch materials such as lithium battery insulating sheet, Mylar, PI film, PET film, barley paper, and Nomex. Using industrial cameras and transmitted-light imaging, it identifies holes, scratches, uneven coating, foreign matter, and dimensional defects, outputs OK/NG, and interlocks with rejection.
The insulating materials in lithium batteries have a clearly defined Safety Function: separating the positive and negative electrodes, isolating the battery cell from the housing and preventing short circuits. Holes, burrs and foreign matter on such materials are therefore not an "appearance issue" but a safety risk.
Insulating sheets are mostly thin film or paper, in roll or sheet form. Holes and cracks give the highest contrast with through-light imaging; surface foreign matter and uneven coating require reflection imaging; and dimensions and contour require measurement after positioning.
This type of inspection is characterized by High stability requirements: an extremely low escape rate is a hard requirement, and because volumes are high the over-rejection rate must not get out of control either.
- Covered materials: Mylar, PI film, PET film, fish paper, Nomex, insulation sheet
- Key Defects: Holes, Cracks, Burrs, Foreign Matter, Uneven Coating
- Imaging key points: transmitted light for holes, reflected light for surfaces, positioned measurement for dimensions
- Metric characteristics: escape rate and over-rejection rate must be controlled at the same time
Core Functions
What the Equipment Can Do and How Far It Can Go
Hole and Crack Inspection
Transmitted-light imaging efficiently makes holes and cracks form a clear image, and is the primary inspection item for insulating materials.
Burrs and Edge Defects
Inspect the slitting edges for burrs, saw teeth and unevenness.
Coating Uniformity
For coated film materials, inspect uneven coating and missed coating.
Foreign Matter and Impurities
Identifies mixed-in particles, fibers, and metal chips (within the visually detectable range).
Dimensions and Shape
After positioning, measure the outline dimensions, hole positions and spacing.
Continuous Roll Inspection
Supports continuous web feeding together with line-scan imaging.
inspection Object
Insulating Films
Holes, scratches and foreign matter in Mylar, PI, PET and other insulating films
Paper-Based Insulating Material
Holes, damage, and dimensions of fish paper and Nomex
Battery Cell Wrapped Parts
Integrity and shape of the wrapping material around the battery cell
Die-cut Insulation Parts
Contour and hole positions of die-cut insulating sheets
inspection defect
| Defect Types | Risk Level | Inspection Focus Points |
|---|---|---|
| Hole / Pinhole | Critical | Risk of insulation failure; transmitted-light imaging gives the highest contrast |
| Crack / Tear | Critical | Risk of structural failure |
| Burr / uneven edge | Critical | Can pierce the adjacent layer, a safety risk |
| Foreign Matter / Impurity | Critical | Conductive foreign matter is the highest risk |
| Uneven coating / missing coating | Moderate | Affects insulation performance and appearance |
| Scratch / Indentation | Moderate | Surface damage; depth impact must be evaluated |
| Out-of-tolerance dimension / hole position | Moderate | Affects Assembly |
Working Principles
- 01 Roll unwinding or sheet loading
- 02 Tension and position control
- 03 Transmitted-light imaging (holes)
- 04 Reflected-light imaging (surface)
- 05 Foreign Matter Recognition
- 06 Dimension and hole position measurement
- 07 Result Composition OK / NG
- 08 NG Marking or Rejection
- 09 Data logging and statistics
Relationship Between Imaging and Judgement
The core of insulating material inspection is Using the right imaging method: holes must be viewed with transmitted light, surface foreign matter must be viewed with reflected light, and dimensions must be measured after positioning. The three have different optimal imaging conditions, so multiple imaging passes or separate stations are often required.
Vision System
How Cameras, Lenses, Light Sources and Controllers Are Configured
industrial camera
Select area-scan or line-scan by field of view and minimum defect size; continuous web materials usually use line-scan cameras
- Area-scan camera: fixed-shot, single-piece and intermittent feed applications
- Line-scan camera: for continuous material travel, wide areas, and even-interval imaging
- Pixel equivalent is derived backwards from "minimum resolvable defect ÷ desired pixel count", rather than fixing the camera first
lens
Determines field of view, distortion, and depth of field; precision measurement requires telecentric lenses
- Standard industrial lens: low cost, suitable for appearance inspection
- Low-distortion lens: for large-format applications where the edges must also be judged
- Telecentric lens: suitable for hole diameter, contour and dimensional measurement
- Depth of field must match material waviness and fixture repeat positioning accuracy
Light Source and Illumination
Whether defects in flexible materials can be captured depends largely on the lighting
- Diffuse light: uniform illumination, suitable for color difference and stain applications
- Low-angle light: highlights scratches, indentations, wrinkles and other surface relief
- Backlight/transmitted light: highlights holes, damage and short shot
- Coaxial light / stripe light: suppresses reflection, suitable for coated or highly reflective surfaces
Controllers and Industrial PCs
The platform for running algorithms, outputting results and interlocking with the production line
- An industrial computer or vision controller runs the algorithms
- A light source controller handles brightness adjustment and strobe synchronization
- Interacts with the PLC to complete interlocking, alarming, and rejection
AI algorithm
Choose the Algorithm by Defect Form, Not by Complexity
Template Matching and Positioning
Locate first, then judge. Every defect judgment is built on a stable coordinate system.
- Shape matching / gray-scale matching: good stability, suitable for fixed stations
- Align first, then split the regions, to avoid false calls caused by position drift
Blob and Morphological Analysis
Suited to defects such as stains, holes and foreign matter that show a clear grayscale/color difference from the background
- Threshold segmentation → connected component statistics → judgement by area / aspect ratio / circularity
- High requirements on illumination stability; the light source must work with the fixture
Edge and Contour Measurement
Suitable for dimension, contour, hole position and spacing judgements
- Sub-pixel edge extraction to obtain a contour point set
- Fit lines/circles/arcs and calculate length, diameter, angle and position tolerance
Deep Learning (Classification / Detection / Segmentation)
Suited to defects such as scratches, wrinkles and skipped stitches, whose shapes vary and are hard to describe with rules
- When defect forms are irregular, it is difficult for rule-based algorithms to enumerate them all
- Requires OK / NG sample training; sample quantity and coverage determine the upper limit
- Enables pixel-level segmentation and outputs defect length, width, area and position
Automatic Alarm and rejection
How inspection results act on the production line
Inspection results are not only shown on a screen. Workpieces judged NG need to be Mark the position and interlock rejection or sorting, and archives the image and judgement result for that part for later traceability and re-judgement.
The alarm method is set according to site practice: audible and visual alarm, on-screen pop-up, PLC set bit, or all three at once. Critical defects and general defects can use different handling strategies — the former stops the machine and alarms, the latter is only marked.
- 01 image acquisition
- 02 Positioning and region segmentation
- 03 Defect Judgement
- 04 Combine results into a single OK / NG per piece
- 05 Result sent to PLC
- 06 NG Rejection / Sorting
- 07 Image and data archiving
data traceability
Records, Queries and Quality Closed Loop
Per-Piece Records
The judgment result, defect type, defect position and timestamp of every part are written to the database
- Supports retrieval by time, batch and defect type
- NG image retention for re-judgement
Batch and Recipe
Different products use different recipes, called up at changeover to reduce manual parameter tuning
- Recipes store the inspection region, thresholds and algorithm parameters
Production Line Data Integration
Exchange inspection data with the MES / host system
- Output pass rate, defect distribution and other statistics
- The interface method depends on the site system
equipment configuration
Optional Configuration Items and Selection Logic
| Configuration Item | Description |
|---|---|
| Applicable Materials | Mylar / PI film / PET film / fish paper / Nomex / insulating sheet |
| Material Form | Roll material / sheet material (select per requirement) |
| Imaging Method | Transmitted + reflected light combination (assigned by defect type) |
| Inspection Speed | To be added |
| inspection accuracy | To be added |
| communication method | I/O · TCP · RS485 · Modbus · S7 · Profinet |
| Enclosure and Power Supply | To Be Confirmed on Site |
Application Industry
Which Industry This Equipment Is Usually Installed In
Applicable Materials
Detectable Material Types
Common Question
How small a hole can be detected in insulation sheets?
How are burrs and uneven edges inspected?
Can conductive foreign matter be detected?
What is the difference between continuous roll inspection and sheet inspection?
Can the escape rate and the over-rejection rate be controlled at the same time?
What Information Do You Need to Provide?
Submit sample testing
Holes and burrs in insulating material are safety-related defects and require rigorous physical validation. Please provide samples containing defects and the quantitative standards; we will run comparative tests of transmitted-light and reflected-light imaging.
Submitted successfully
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Need to assess imaging conditions, defect criteria and cycle time item by item? Go to the Full Requirement Assessment →
Send Us Your Workpiece and We Will Show You the Measured Results
Equipment configuration varies with the inspection object, field of view and cycle time. Provide OK and NG samples and we will run actual imaging and judgement tests and recommend the corresponding model and configuration.