Case Study | High-Speed Battery Separator Inspection with LineX
LineX CIS cameras inspect battery separators on coating, slitting, and rewinding lines without conventional lens distortion. The reported results include at least 99.9% defect detection, 90% less manual review, and 300% higher inspection throughput.
Why separator inspection matters
The battery separator keeps the electrodes apart while allowing lithium ions to pass. Pinholes, contamination, and coating defects can affect performance and safety. Inspection must keep pace with coating, slitting, and rewinding lines.
The limits of a conventional line-scan setup
Lens distortion can change the apparent size of a small defect at the field edge. Raising resolution increases data and processing load; lowering it risks missing pinholes. Dust on the lens and light, vibration, and repeated recalibration also reduce line availability, while the camera assembly needs space that compact coating and slitting machines may not have.
What CIS changes
Close-range, full-width imaging is well suited to low-contrast contamination, thin spots, and pinholes in the 5–20 µm range described in the application. Consistent pixel scale supports defect and dimensional checks on the same moving web. An integrated head has fewer separate optical parts to align, and protective film can help shield the sensor from dust.
The solution applies to coating, slitting, and rewinding equipment. Stored images provide evidence for process review, while saved recipes let operators change products and restart inspection quickly.
LineX CIS imaging
Close-range CIS imaging reduces conventional lens distortion and provides consistent pixel scale across the scan. Its compact, integrated design fits constrained equipment and limits adjustment and cleaning work. High-speed line scanning captures small, low-contrast defects and supports dimensional checks on the same web.
The system stores defect images and results for traceability and supports recipe changes between products.
Reported results
The customer reported at least 99.9% defect detection, 90% less manual review, and 300% higher inspection throughput. Operators can resume production within minutes after a product change using stored recipes.
