MV-CS050-10GM(NPOE)View part & specifications →Browse camera options →Hem / Case studies / Battery welds and tabs
Application study · Lithium battery manufacturingBattery weld marks and tabs: controlling reflections with diffuse light
Laser weld marks on battery cases are faint, the metal is frosted and the tabs are mirror-bright. Side-by-side tests show how a flat dome light turns an unreadable weld into a clean outline, and why the camera hole in a dome matters on a shiny tab.
Control what shiny metal reflects.
- LjusFlat dome, 100 × 100 mm emitting
- Storlek140 × 140 × 11.5 mm
- ArbetsavståndClose, under the camera
- ResultWeld outline readable after the change
Test stationIncluded light holdersKameraObjektivLjusPartSynfält
Drag to rotate · scroll to zoomWalk through this setup 5 guided stops
From component to inspection
Understand each choice.
Choose a stop to frame the part in 3D and see why it belongs in this setup. The component notes and links remain available if 3D cannot load.
Proposed component
MV-CS050-10GM(NPOE)
5 MP 2/3" monochrome: about 41 µm per pixel across a 100 mm field (100 mm / 2448 px).
Proposed component
LS-KF1628M-ML
16 mm macro lens, 0.25x to 0.03x; a 100 mm field on a 2/3" sensor needs about 0.085x.
Tested component
LS-2LFX100-C
Flat dome, 100 × 100 mm emitting area, 140 × 140 × 11.5 mm.
Proposed component
LS-BT-XZ-G-6-6045
600 mm column, 600 × 450 mm breadboard, XZ adjustment, glass tray and two lighting holders as listed. Proposed bench fixture; confirm loads, travel and camera/lens clamps.
Inspect the real capture
Follow the contrast to the part.
Control what shiny metal reflects.
Camera and available lens CAD are published models. Lens and light envelopes use printed dimensions. The linked station uses its published base size and column height; carriage, brackets, fittings, parts and spacing are illustrative. Confirm load, travel, fasteners and clearances before ordering. Light paths explain the arrangement and do not simulate optical performance. The light-guide panel is shown transparent to explain viewing through it; its internal construction is schematic.
From the demo to your test benchKameraMV-CS050-10GM(NPOE)View part & specifications →Browse camera options → Imaging lens
LS-KF1628M-MLView part & specifications →Browse imaging lens options → Inspection light
LS-2LFX100-CView part & specifications →Browse inspection light options → Test station & mounts
LS-BT-XZ-G-6-6045View part & specifications →Browse test station & mounts options →
Build around the parts you can buy.
Explore each component, check its specifications and compare alternatives. The proposed quote includes the linked test station; its catalog listing includes two lighting holders.
MV-CS050-10GM(NPOE)View part & specifications →Browse camera options →LS-KF1628M-MLView part & specifications →Browse imaging lens options →LS-2LFX100-CView part & specifications →Browse inspection light options →LS-BT-XZ-G-6-6045View part & specifications →Browse test station & mounts options →Mount the optics with intent
The station is an optical test bench, with its two lighting holders included in the catalog listing. The 3D column and base follow the published height and footprint. Carriages, clamps and part supports are schematic: confirm camera screw pattern, lens support, light fasteners, permissible load and actual travel before ordering.
Configure the mounting station →Complete the electrical system
Select a controller against the exact light voltage, drive mode and power, then confirm camera data/power/I/O cables and a suitable PC. These are not silently added to the proposed optical kit.
Lighting application-lab image sheet
Evidence you can inspect
Visible in the images
The supplied lighting comparisons show a clearer weld outline and a change in the reflected dark aperture on a shiny tab.
What the source reports
The source compares lighting arrangements; it does not report weld strength, penetration or a detection rate.
How to use this evidence
Surface appearance is evidence for an imaging trial. It cannot establish weld integrity beneath the surface.
What the camera saw
Cropped from the source test sheet; original test annotations are retained. Captures are not generated or enhanced. Drag the comparison slider or use the image buttons.
Shadowless lightFlat domeFlat dome: Flat dome (LS-2LFX100-C): the weld outline is clear and even.
Round domeSquare, hole sized to the partSquare, hole sized to the part: Square shadowless light with the centre hole sized to the part (made to order): no dark spot.
The challenge
A weld seam on an aluminium case is a low-relief mark on a frosted surface. A plain shadowless light scatters off the frosting and the seam disappears into texture.
The tabs are the opposite problem: polished metal mirrors whatever is above it, including the dark camera hole of a dome light.
How it was solved
Weld marks: the test first used the LS-LFX100 shadowless light, where the frosting hid the surface detail. Changing to the LS-2LFX100-C flat dome, which lights the part evenly from a wide range of angles, strengthened the surface lighting and brought the weld outline out clearly.
Tabs: under the LS-DM120-W dome the tab is evenly lit, but the dome's small centre hole shows as a dark spot reflected in the metal. A square shadowless light with its centre hole sized to the long side of the part removes it; we build that to order.
Why it works
- 1
Broad diffuse illumination changes the reflection pattern on frosted metal. In this comparison, the flat dome makes the weld outline easier to distinguish.
- 2
Only 11.5 mm tall, so it fits between the lens and the part on a crowded line.
- 3
On mirror-like parts, anything above the part is in the picture: size the camera hole or move it off the region you measure.
From image contrast to a production decision
What to validate on your part
A useful sample image is the starting point. These are the checks that turn the concept into a defensible inspection.
- 01
Keep good texture in the trial
Include normal frosting, finish variation and acceptable weld marks.
- 02
Challenge the reflection
Vary tab tilt and check for the camera-hole reflection across the full part.
- 03
Confirm the inspection requirement
Separate visible surface defects from weld-quality checks requiring other methods.
Explore your inspection requirementsNo limit from motion
How many pixels cover your feature?
Compare feature coverage, camera pixel requirements and exposure using your own planning inputs. These are calculated planning values, not inspection results or an accuracy specification.
Editable planning scenario. Adjust these example inputs for your application; they are separate from the source test and 3D setup. Motion allowance and target coverage are starting points to validate, not acceptance limits. Pixel count starts from the proposed camera's catalog resolution.
Enter finite numbers in every field. Field width, feature width, target coverage, exposure and allowed motion must be greater than zero; horizontal pixel count must be a positive whole number; material speed may be zero. Use values within the supported numeric range if a calculation cannot be represented.
Object sampling mm/px
Pixels across feature px
Horizontal pixels for target px
Motion during exposure px
Exposure ceiling from motion µs
Formulas and assumptions
The field, feature, speed and exposure start with neutral example values. They are not taken from the source test or the 3D illustration. Allowed motion starts at an editable 0.5-pixel example; it is not a recommended acceptance limit. Target coverage starts at an editable 5-pixel example; it is not a recommended detection or measurement threshold. The horizontal pixel count starts from the catalog Resolution row for MV-CS050-10GM(NPOE). Use the effective width after cropping, binning or decimation if those modes are enabled.
- Object sampling (mm/px) = field width (mm) / horizontal pixels.
- Pixels across feature = feature width (mm) / object sampling (mm/px).
- Horizontal pixels for target = field width (mm) × target pixels across feature / feature width (mm), rounded up to a whole pixel.
- Motion (px) = speed (mm/s) × exposure (µs) / 1,000,000 / object sampling (mm/px).
- Exposure for allowed motion (µs) = allowed motion (px) × object sampling (mm/px) / speed (mm/s) × 1,000,000.
The exposure result is the maximum duration from this motion allowance alone. At zero speed, motion sets no exposure limit; the camera, lighting, saturation and other constraints still apply. A shorter exposure does not itself guarantee a reliable inspection.
Field width and feature width refer to the same object plane. The motion calculation assumes uniform linear motion parallel to the field-width direction and a single exposure. It does not model perspective, vibration, rolling-shutter distortion, diffraction, defocus or optical distortion. A strobe may change the effective exposure.
The target result is a horizontal sampling requirement, not a camera recommendation or a change to the selected camera. It uses the effective image width after cropping, binning or decimation and does not determine the vertical resolution or sensor size. Pixel coverage alone does not establish detectability or measurement accuracy. Validate contrast, lens performance, working distance, illumination, calibration, camera exposure limits and the inspection algorithm on representative parts. Changing field width does not change the 3D model or certify that the proposed lens can achieve that field.
The set-up and the parts
| Weld light | Flat dome (LS-2LFX100-C), white |
|---|---|
| Tab light | Dome (LS-DM120-W) or square shadowless, made to order |
| Kamera | Area scan, mounted straight down through the light |
| Mounting (proposed) | LS-BT-XZ-G-6-6045 · camera test station with glass tray and two lighting holders |
LjusTestedLS-2LFX100-C
Flat dome, 100 × 100 mm emitting area, 140 × 140 × 11.5 mm.
$329.00In proposed setup
LjusTestedLS-DM120-W
Dome, 120 mm outside, 30 mm centre hole, 52 mm high.
$359.00Separate test / alternativeKameraOur pickMV-CS050-10GM(NPOE)
5 MP 2/3" monochrome: about 41 µm per pixel across a 100 mm field (100 mm / 2448 px).
$819.00In proposed setupObjektivOur pickLS-KF1628M-ML
16 mm macro lens, 0.25x to 0.03x; a 100 mm field on a 2/3" sensor needs about 0.085x.
$319.00In proposed setupCamera test stationOur pickLS-BT-XZ-G-6-6045
600 mm column, 600 × 450 mm breadboard, XZ adjustment, glass tray and two lighting holders as listed. Proposed bench fixture; confirm loads, travel and camera/lens clamps.
$359.00In proposed setup"Tested" identifies the part named in the source. "Our pick" is a proposed alternative or supporting part. The quote includes only cards marked "In proposed setup", with the quantities shown; other test arrangements are separate. Confirm colour, optics, controllers, power supplies, cables and mounting before ordering.
About this case study: the photos and camera images come from the application laboratory of the maker of the lighting and optics we sell, imaged on the parts shown; your results depend on your part, camera and set-up. This is an application-lab study, not a LumaSpec customer deployment. Source figures are reported results; proposed components require a fresh trial. The 3D scene illustrates the arrangement and does not simulate imaging performance.
Guider
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Start with your inspection requirement
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