INTELLIGENT BRANDS // Green Technology
Electric vehicle growth depends on quality, compliance, safety with manufacturers
Automotive OEMs, machine builders, and systems integrators are looking for new and better support as missed errors during the manufacturing, inspection and testing stages can prove dangerous to road users and cost money in terms of refunds, compensation and vehicle recalls. Customers do not want to purchase a vehicle or fleet of vehicles that will require replacements, repairs and recalls due to quality issues.
“ We know that quality, compliance and safety begin upstream at the point of manufacturing,” said Stephan Pottel, Manufacturing Strategy Director, EMEA, Zebra Technologies.
“ Materials, components, systems and finished products need to be delivered with the highest levels of quality, with defects and anomalies quickly identified and resolved. This is true for the automotive and electric battery manufacturing sectors and suppliers who contribute across the supply chain.”
Leaders say today’ s most significant quality management issues are real-time visibility, 28 %, keeping up with new standards and regulations, 28 %, integrating data, 26 %, and maintaining traceability, 23 %, according to this Zebra Manufacturing Vision Study.
Manufacturing leaders are struggling to keep up with the pace of technological innovation. They hear about AI and 3D solutions but want to know how it can support quality and safety in their operations. They may be using machine vision systems based on rules which are hard to scale and do not handle increasingly complex requirements.
Pottel shares some examples of how new machine vision and 3D technologies can be used to safeguard EB manufacturing operations.
Cell Inspection
Detecting defects and flaws in battery cells, such as microcracks or foreign particles, is critical for safety and performance outcomes. Machine vision inspection helps ensure no scratches or holes compromise cell integrity, and assessing size and integrity of tab and connectors of EBs can be difficult due to reflection issues common to metallic surfaces.
Using 3D sensors can help combat the lack of contrast by accurately scanning surfaces to reveal surface imperfections.
Module Assembly
Leveraging advanced machine vision solutions, including 3D sensors and deep learning algorithms capable of analysing complex weld features and detecting defects with high precision, is necessary for effective module assembly. Engineers and inspection teams can evaluate bead thickness, dimension and position and assess the quality of assembled modules using 3D profilers or 3D snapshot sensors with 3D imaging software.
Assembling battery cells requires the alignment of cell components in assembled modules which can be achieved with 3D profilers, 3D snapshot sensors, 3D model- and pattern-finding software and perfect golden template tools.
Stephan Pottel, Manufacturing Strategy Director EMEA, Zebra Technologies
Battery Pack Assembly
Conducting end of line inspections safeguards against intrusion of foreign objects. Final assemblies must be verified before they are moved into position for placement in EVs – inspecting the structural integrity and alignment of components such as cable clips, electrical connections, coolant connection and cables.
Mounted on an autonomous mobile robot, AMR, GigE vision cameras can generate a single robot pose to accurately pick up completed EV battery modules from a dunnage for more efficient, faster manufacturing processes with reduced need for manual inspection or intervention. p
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