background knowledge

The CCS integrated busbar is a core component of new energy power battery packs, constructed from over 20 materials including busbars, insulating films, and copper-aluminum wires, with its quality directly impacting the safety and consistency of the battery pack. Next Vision Tech's LVM3050 3D line laser camera offers a proven inspection solution specifically designed for mass production quality control of CCS integrated busbars. Through synergistic optimization of its proprietary optical system and algorithms, it enables stable three-dimensional inspection of highly reflective or strongly absorptive materials, facilitating comprehensive detection of all height variations across the CCS integrated busbar.

Key pain points in industry monitoring:

Model | LVM3050 Line Laser 3D Camera Core Hardware Advantages

· Continuous adjustable large field of view ranging from 183 to 416 mm: A single unit can cover busbars with widths of 100–160 mm, eliminating the need for segmented scanning and reducing equipment investment and motion module costs.

• High-reflection material with optimized light path: Featuring a self-developed optical system and algorithmic enhancement, it effectively addresses complex chromatic aberrations in copper-aluminum hybrid welded components while reliably detecting welding defects, surface elevation differences, and flatness.

·3200pts/high-line density imaging: Accurately reproduces minute surface elevation differences and proximal structural details with highly defined boundaries without loss

·10 μm repeatability accuracy: meets the requirements for detecting micron-level height differences with reliable consistency

· Flexible frame rate range: 600–10,000 Hz – supports high-speed scanning and adapts to various production line rhythms

Project Testing Requirements

·Workpiece inspection: CCS integrated busbar; workpiece dimensions: 100 mm × 160 mm

·Testing Content: Comprehensive measurement of the cross-material height difference between the flat surface of the copper metal corner and the top surface of the plastic reinforcement rib on its side.

·Customer technical specifications: Total inspection cycle time per unit on automated production line ≤7 seconds/PCS; repeatability accuracy of differential measurement system <0.3 mm

Practical Performance: Dual guarantees of stable imaging and high precision

(1) Image Capture Results

The figure shows a brightness map, a fusion map, and selected point cloud images.

（2）Actual measurement data for thickness repeatability

Data Performance (12 consecutive samples)

·The Z-axis repeatability accuracy is within 0.01 mm, meeting the customer's requirement for a detection precision of 0.3 mm.

(III) Production Line Adaptation Efficiency Indicator

The core competitiveness of the Next Vision Tech LVM3050 solution

·Accurate timing: 10 μm high precision with a frame rate of 600–10,000 Hz, ensuring efficient production without production downtime

·Comprehensive inspection replacing visual inspection: Supports automated detection across the entire busbar height, completely replacing manual visual inspection.

• Multi-specification compatibility: wide field of view ranging from 100 to 160 mm, offering excellent overall adaptability

·Increased Total Cost of Ownership (TCO): All LVM lines feature laser inspection, simplifying equipment procurement and maintenance costs

In addition to detecting height differences in power battery CCS integrated busbars, the LVM3050 can simultaneously identify minor misalignments in busbars; handle complex conditions such as metal welding defects, surface unevenness, and flatness issues; perform insulation film assembly inspections; and monitor quality across various PACK assembly stages. For tailored inspection solutions, contact Next Vision Tech to obtain customized 3D visual measurement systems that reduce assembly defect rates on battery PACK production lines and enable fully automated precision quality control.