Pre-Stacking Vision & Ultrasonic Inspection System
Pre-Stacking Inspection — Vision + Ultrasonic In-Line QC
Every electrode sheet is individually inspected before it enters the stacking sequence. This is the gate that separates PCEONAMP’s first-pass yield from the industry average.
Optical Inspection
A precision backlit platform with uniform high-brightness white LED illumination transmits light through the electrode sheet, producing shadow-free, high-contrast edge imaging. Two high-resolution industrial area-scan cameras capture the full sheet at line speed.
The vision algorithm performs pixel-level analysis on every unit:
- Electrode body: edge chipping, material loss, micro-burrs, dimensional deviation, contour incompleteness
- Tabs: missing, positional offset, bending, folding, tearing, surface damage
Ultrasonic Single-Sheet Verification
Beneath the optical platform, an embedded ultrasonic sensor measures wave penetration depth to verify the presence of exactly one electrode sheet. By distinguishing the reflection signature of a single layer versus accidental multi-sheet overlap, the system eliminates double-feed — the root cause of out-of-tolerance cell thickness and hidden internal short circuits.
This is a detection layer that pure optical inspection cannot provide, particularly for thin, flexible electrode foils where stacking artifacts are visually indistinguishable.
Auto-Sort & Line Synchronization
The inspection station is fully synchronized with the vacuum suction handling system. Logic:
- Pass → control system issues clearance signal → sheet transferred to Z-stacking
- Fail → sheet auto-sorted to rejection bin → no operator intervention
Zero manual picking. Zero downstream rework from pre-stack defects.
Impact on Final Cell Quality
| FAILURE MODE PREVENTED | CONSEQUENCE IF UNDETECTED |
|---|---|
| Edge chipping / burrs | Internal short → thermal event |
| Tab misalignment | Poor weld → connection failure under load |
| Multi-sheet feed | Cell thickness OOT → inconsistent internal resistance |
| Contour deviation | Separator coverage gap → micro-short risk |
By intercepting all four failure modes at the pre-stack stage, the line eliminates the most common root causes of field failures in high-rate LiPo cells.
This inspection standard applies to all PCEONAMP cell lines — 10,000 to 32,000mAh UAV packs and high-rate RC cells alike. Every sheet, every cycle, no exceptions.