How can sensors solve the pain points in lithium battery production
Release time:2026-05-12
How can sensors solve the pain points in lithium battery production, such as abnormal material feeding, uneven coating thickness, and unqualified pole height?
Lithium battery manufacturing features complex processes, high technical barriers and stringent quality standards. Improper process control will directly impair the performance and quality of finished batteries.
Battery manufacturers have set higher requirements for production equipment in terms of precision, efficiency, intelligent maintenance and fault diagnosis capabilities.

Promoting intelligent upgrading to boost production efficiency and product quality has become an imperative task for lithium battery enterprises.
As the core sensing component and the source of data collection, sensors are widely applied throughout the automated production of lithium batteries.
This article gives a detailed analysis of sensor application solutions for key working stations in automated battery manufacturing.
Cell Blanking Detection
Application Scenario
At the cell blanking station, it is required to detect whether materials are properly fed to the designated position. Inaccurate cell feeding will cause idle running or material jamming in subsequent processes, disrupting the tact time of the entire production line.
Solution
Adopt Heyi FM-E23 Series Fiber Optic Sensor + FN-T001(R) Fiber Optic Head
Comprehensive circuit protection with reverse polarity protection and over current protection
Excellent working stability
High precision with regional detection capability
Fast response speed up to 50μm
Single & Double Sheet Detection of Pole Sheets for Stacking Machine

Application Scenario
In the stacking process, it is necessary to identify single and overlapping pole sheets. If two pole sheets enter the stacking station simultaneously, it will lead to the risk of internal short circuit of the battery, which is a critical quality defect.
Solution
Adopt Heyi UDC Series Ultrasonic Sensor for Single & Double Sheet Detection
Built-in temperature compensation, free from ambient temperature impact
Ultrasonic system for reliable detection of missing sheet, single sheet, double sheets and overlapping sheets
Applicable to single/double sheet detection of various materials
Self-learning function via multi-function input; parameters can be remotely set through cables
Completely unaffected by dust, dirt and fog
Strong anti-interference performance against electromagnetic and radio frequency interference

Lithium Battery Electrode Coating Thickness Detection
Application Scenario
Battery electrodes are mainly made of copper foil and aluminum foil. Coating is applied on the electrode surface to improve current conduction efficiency between two poles. Full inspection of pole sheet thickness is essential to ensure accurate and uniform coating thickness.
Solution
Adopt Heyi LC-S Series CMOS Laser Displacement Sensor
Non-contact detection
Optional short, medium and long detection distances
Compact structure, tiny light spot and high precision
Multiple output modes: single switch output, dual switch & analog output, RS485 communication output
Rich built-in functions and detection modes to adapt to diverse application scenarios
Pole Height Detection of Lithium Battery Modules

Application Scenario
After the assembly of lithium battery modules, pole height inspection is required to ensure product qualification.
Solution
Adopt Heyi HK-S Series High-precision Digital Contact Displacement Sensor
Micron-level repeat accuracy
High-precision grating measuring principle
Multi-digit digital display for measured values
Resolution up to 0.1μm
Detection accuracy up to 1μm with no cumulative error
Optional RS485 / RS232 communication output
Support operation with matched amplifier or standalone use of detection head
Equipment & Personal Safety Protection
Application Scenario
When personnel approach hazardous areas, the sensor outputs signals to cut off power of operating equipment such as manipulators and cutting machines, so as to avoid safety accidents.
Solution
Adopt Heyi GM-L Series General-purpose Safety Light Curtain
Complete self-check function and high resolution
Resist electromagnetic, laser and ambient light interference
Optional multi-channel and multi-signal output
Optical synchronization and line synchronization available for the full series
Optional S-type external controller for multi-scenario protection
Shockproof, waterproof and dustproof performance
LED indicator for working status and fault alarm
Barcode Identification & Reading

Application Scenario
At the casing station of prismatic lithium batteries in the middle production process, bare cells are loaded into the shell, and the cell cover is pre-welded with the shell mouth. QR codes on the battery cover need to be identified before casing operation.
Solution
Adopt Heyi SV Series AI Vision Sensor
Auto focus and brightness correction
High-speed detection capability
Megapixel resolution, supporting long-distance and wide-field detection
Integrated multiple detection functions:
Color recognition, contour comparison, area measurement, brightness identification, position correction, width & diameter detection, edge presence detection, pitch measurement, character recognition, barcode recognition, etc.

The rapid capacity expansion of power batteries in China has raised extremely high standards for the automation level of production equipment.
Integrating sensing technology with lithium battery manufacturing technology,Heyi Sensor is committed to providing comprehensive sensor solutions for the lithium battery industry. We help realize higher efficiency and intelligence in lithium battery production, and drive the development of the new energy lithium battery industry.
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