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Speed is key in battery production. One of our customer produces up to 1 billion portable batteries annually. In order to meet consumer demands for product quality, the company relies on a high level of automation. The company has strict tolerance limits for battery production, specifically for the interfaces for energy transfer (i.e., the plus and minus poles). Batteries that have mechanical faults or performance defects must be rejected. However, company is also concerned with preserving production efficiency and containing costs, so it is also important to keep the proportion of rejects as low as possible. By applying vision systems, they have succeeded in achieving 100% fault detection and minimum rejection of acceptable parts on seven production lines with this vision system in place.

1.   Customer

A company manufacturing batteries for global automotive, industrial, and consumer markets.

​2.   Issue

  • Using 2-D vision to detect quality defects caused by contamination and mechanical distortion identified pseudo-rejects at an unacceptable rate of 8 -10%

  • Even the smallest particles of contamination, which had no negative effect on either the battery's performance or appearance, were graded by 2-D vision systems as defects.

3. Result

In the process of testing the 3-D vision system, Varta used VisionPro 3D software to compile an extensive reference sample catalogue. Factory is able to successfully differentiate between contamination and mechanical defects.
The newly acquired 100% testing/inspection quality provides an additional product differentiator in a highly competitive market. 

The minimized rejection rate is making a vital contribution to the long-term future of the production facility.