LS2201 Application Solution for Inline 3D Dent Inspection of Lithium Battery Copper Foil

LS2201 On‑line 3D Indentation Inspection Solution for Lithium‑ion Battery Copper Foil

(Version with Illustrations for Promotional Use)This solution targets on‑line quality inspection of lithium‑ion battery copper foil. Based on LS2201 line‑laser profile measurement technology, it performs high‑speed, non‑contact and traceable 3D detection for defects such as indentations, pits and local bulges generated during winding‑unwinding, roller conveying and calendering processes of copper foil.

Solution Highlights

3D height measurement for direct indentation‑depth identification

Adapted to highly‑reflective copper‑foil surfaces

Strong immunity to ambient light interference

Supports high‑speed on‑line inspection

Suitable for continuous web‑based production lines

Dual‑side DS / OS inspection supported

Expandable to multi‑sensor stitching

Traceable inspection results

Outputs defect position, depth and length

PLC / MES compatible

Enables closed‑loop production‑line control

1. Equipment Installation and Site Layout

The diagram below shows the reference mechanical layout. The inspection head is mounted above the running copper‑foil web. The industrial PC and control system are housed inside an electrical cabinet. It connects to the LS2201 sensor via Gigabit Ethernet, and achieves position‑synchronized data acquisition with an encoder.Figure 1 Reference mechanical layout: inspection head and industrial PC arrangement

2. Overall System Architecture

The system consists of LS2201 line‑laser profiler, industrial PC, encoder synchronization module, inspection software and PLC/MES communication link. The sensor performs high‑speed scanning of copper‑foil surface profiles. The host PC completes point‑cloud reconstruction, reference‑plane fitting, defect identification and result output.Figure 

2 System architecture of LS2201 on‑line 3D indentation inspection system for lithium‑ion battery copper foil

3. Inspection Principle and Algorithm Workflow

The LS2201 works on the laser triangulation principle: a laser line is projected onto the copper‑foil surface. When an indentation exists, the projected laser line shifts its imaging position on the CMOS sensor. Based on calibration parameters, the system calculates Z‑axis height at each point and further computes indentation depth.

Figure 3 Schematic diagram of laser triangulation principle

To enhance field‑proven stability, the algorithm adopts the workflow of filtering & denoising + dynamic reference‑plane fitting + height‑difference threshold judgement. It reliably detects local indentations even under conditions of minor copper‑foil flutter, tension fluctuation or guide‑roller vibration.

Figure 4 Algorithm workflow for copper‑foil indentation inspection

4. Software Interface and Inspection Result Presentation

The reference software interface displays real‑time inspection results of both DS and OS sides, trend curves, alarm status and historical logs. Red‑boxed areas show height‑trend graphs for real‑time observation of height fluctuations caused by indentations.

Figure 5 Schematic of on‑line inspection software interface (Dual‑channel DS / OS)

Within software logic, upper/lower thresholds for indentation depth, continuous over‑limit counting, filtering window and alarm strategies can be configured according to process requirements. Signal interaction with PLC enables automatic alarming, production halt or defect marking.

Figure 6 Schematic of height‑variation curve for copper‑foil indentation inspection

5. Technical Value and Recommended Output Metrics

Compared with conventional manual sampling inspection or ordinary 2D vision, the LS2201‑based 3D solution identifies micro‑indentations and surface topography anomalies more directly, improving consistency and automation of lithium‑ion battery copper‑foil quality control.

Recommended Output Items

LS2201 Application Notes

Centered on the LS2201 line‑laser profiler, this solution applies to surface‑defect inspection of web materials such as lithium‑ion battery copper foil and aluminium foil. Measuring range, working distance, laser line width, resolution and scan frequency shall be further confirmed according to on‑site installation space, foil width and target‑defect size.

Comprehensive Advantages

Direct Z‑axis height data enables quantitative indentation analysis, instead of mere grayscale‑based image judgement.

High adaptability to highly‑reflective metallic foils, less susceptible to texture variation and ambient‑light change.

Supports high‑speed on‑line inspection without disrupting the tact time of continuous web‑based production lines.

Traceable inspection results; connects with manufacturing systems for closed‑loop management.

Expandable to dual‑sensor or multi‑sensor stitching for wider production‑line widths.

Conclusion

For lithium‑ion battery copper‑foil indentation‑inspection scenarios, the LS2201 laser 3D vision solution delivers effective on‑line, stable and quantifiable defect detection. Suitable for inspection stations after guide rollers, after calendering or other critical quality‑monitoring positions, it serves as a quality‑upgrade option for lithium‑battery‑material equipment suppliers and end‑user manufacturers.