Application Guides
Plan EV battery weld-height inspection by profile width, Z tolerance, reflective surface behavior, trigger timing and reject output.
Direct answer
Use 3D vision for EV battery weld height when pass/fail depends on profile, gap or bead geometry instead of color contrast. Confirm profile width, Z tolerance, line speed, reflective finish and reject output before choosing the sensor route.
EV battery weld height projects should start from measurable profile, gap, bead width and Z repeatability requirements because surface brightness alone cannot prove weld geometry.
Foil, nickel, aluminum and welded tabs may generate noisy profile data when angle, finish or speed changes. The review should include worst-case production samples, not only a clean demo part.
Provide weld photos, profile width, height range, Z tolerance, line speed, trigger timing, reject output and representative good, bad and borderline samples.
A tab weld can look acceptable in 2D while bead height, gap or profile is out of tolerance. 3D vision adds Z data so the station measures geometry instead of relying on surface brightness.
The sensor must cover the weld area while resolving the smallest trusted height change. Wider fields, tighter Z repeatability and faster production speeds can move the project into a different 3D sensor route.
Foil, nickel, aluminum and welded tabs can be reflective, dark, angled or inconsistent. The RFQ should include real weld samples or line videos from best and worst batches before model selection.
A practical weld-height station may need OK/NG, height value, profile image, reject trigger, image storage and recipe control. These outputs decide controller and software scope as much as the sensor.
How to test before buying
Run the proposed 3D route on real weld samples at intended speed, then confirm Z repeatability, reject timing, profile noise and whether 2D support is needed for position or traceability.
Decision checks
Use for position, presence, label, barcode or visible surface contrast.
Use for weld height, gap, bead profile, flatness and geometry.
Match scan rate, exposure, trigger and reject timing to takt time.
Decision table
| Factor | Practical rule | RFQ impact |
|---|---|---|
| 2D vision | Use for position, presence, label, barcode or visible surface contrast. | Send sample images and target contrast. |
| 3D laser profile | Use for weld height, gap, bead profile, flatness and geometry. | Send Z tolerance, profile width and height range. |
| High-speed line | Match scan rate, exposure, trigger and reject timing to takt time. | Send speed, trigger method and output needs. |
| Reflective finish | Validate with real material because profile noise can change by batch. | Send several production samples, not one clean part. |
Application proof
Battery tab weld inspection needs geometry confidence, stable position reference and traceability under high station throughput.
Reflective metal surfaces can hide scratches and burrs unless the lighting geometry is matched to the defect direction and part movement.
Small connector features require stable contrast, low distortion and repeatable part positioning before a pass/fail threshold can be trusted.
Common mistakes
Factory handoff
The factory route review starts by checking whether the image can be made stable with lighting and fixture control. Then the camera, lens, reader or 3D sensor route is sized against speed, resolution, interface and installation constraints.
If you already have a Keyence, Cognex, Basler, OPT, LMI, Hikrobot or barcode-reader reference, include it as a reference model. Deyi Vision uses it to understand the application class; final selection still depends on real samples and production limits.
Guide to RFQ
Use the guide to frame the question, then send the details so engineering can recommend a route.
Request engineering RFQGuide FAQ
Use 3D when the acceptance rule depends on weld height, bead profile, gap, flatness or geometry that cannot be proven reliably by 2D contrast.
2D can inspect presence, location and some visible defects, but it cannot directly measure height or profile without 3D evidence.
Send weld photos, profile width, height range, Z tolerance, surface material, line speed, trigger method, reject output and representative good/bad/borderline samples.
