Case Study | Wide-Web Battery Coating Inspection with LineX 2
A monochrome LineX 2 CIS camera covers more than 1.5 m without image stitching and detects defects as small as 0.05 mm. The customer reported a rise in defect detection from 99% to 99.8%, 60% less specialist setup time, and a 15% gain in OEE.
The wide-web challenge
Battery electrode coating requires accurate registration and surface inspection across webs up to 1,500 mm wide. Conventional multi-camera systems can introduce stitching error, complex calibration, and long downtime during product changes.
Why stitching was a problem
Across a 1,000–1,500 mm coated web, a conventional solution needs several high-resolution cameras. Calibrating their overlapping views takes time; a mismatch at a seam can distort the measured offset between the front and back coating areas and affect PLC correction. Lens-edge distortion also makes a roughly 0.05 mm uncoated spot or particle harder to size reliably.
Simpler setup and changeovers
LineX 2 captures the wide field in a single scan. Integrated illumination, optics, and focus control reduce the number of settings technicians must adjust on site. Imaging recipes accommodate copper or aluminum foil and different coating materials, while consistent full-width scale supports measurement-system analysis and front/back registration.
LineX 2 without image stitching
A monochrome LineX 2 CIS camera covers more than 1.5 m in one scan. Distortion-free, close-range imaging helps identify coating gaps, particles, scratches, and wrinkles down to about 0.05 mm. Integrated camera, lighting, and optics simplify installation and keep front/back registration data consistent for the coating-line PLC.
The system offers 600 dpi, with 900, 1,200, and 1,800 dpi options. The customer reported 70% shorter commissioning and 50% faster product changeovers.
Reported results
Defect detection rose from 99% to 99.8%. The customer also reported 60% less specialist setup work and a 15% gain in overall equipment effectiveness (OEE).
