PROJECT TOPICEV Charging, Batteries & Clean Energy
Cell-to-Pack Weld Scanner
A quality inspection concept examining 3D laser displacement sensors deployed on multi-axis gantries to verify busbar weld seam profiles across hundreds of battery cells in an EV module.
Battery Module Manufacturing Integrity
- ✓Investigates high-resolution optical height profiling for reflective copper/aluminum joints.
- ✓Correlates weld bead height, width, and cross-section profiles with electrical conductivity standards.
- ✓Demonstrates rapid multi-point scanning across dense cylindrical or prismatic cell arrays.
The Engineering Challenge
Problem / Objective
Defective micro-welds between busbars and battery terminals cause localized thermal hot spots, cell degradation, and fire hazards.
Conceptual Signal Flow
System Concept
Laser Triangulation Sensor → Cartesian Motion Gantry → Point Cloud Profiler → Weld Quality Report.
Architecture Modules
1High-Precision 2-Axis Motion Stage
2Laser Line Displacement Sensor
3Height Profiling Reconstruction Software
4Defect Threshold Evaluation Logic
Hardware Categories
3D Laser ProfilerLinear Motion GuidesOptocoupled I/OIndustrial PC
Technologies & Software
Laser TriangulationPoint Cloud AnalysisPrecision MotionQuality ControlPoint Cloud Surface AnalyzerInspection Database
Engineering Considerations & Edge Cases
- Optical glare and reflections from polished copper and aluminum surfaces
- Scan speed vs micron-level vertical resolution
Applications
EV battery pack assembly
Energy storage system QA
Precision metal joining lines
Engineering Inquiry & Collaboration
Interested in Developing this Architecture?
Connect directly with Tamizh Tech engineers in Coimbatore to discuss mechanical fabrication, sensor selection, firmware implementation, or turnkey system commissioning.