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Tab Direction Vision System
Project Type
Mechanical Design & Manufacturing
Client
LG Energy Solutions (ESMI Holland Site)
Timeline
November 2025 - February 2026
Status
Completed; 6 units deployed and operational in Standalone Unwinder, Stocker of the Factory (Anode & Cathode Side).
Roles & Responsibilities
1. Led the complete development of the Tab Direction Vision System from root cause identification to full-scale deployment across 6 production lines (three machine variants).
2. Analyzed production inefficiencies caused by incorrect tab direction during roller feeding and defined the mechanical and vision system requirements to eliminate rewinding operations.
3. Conceptualized and developed multiple design solutions before finalizing a unified structure integrating the Keyence camera and illumination system on a single precision-aligned mounting structure.
4. Designed adjustable mechanisms for both camera and lighting to accommodate variations in roller diameter (~620 mm) and ensure consistent detection from maximum to minimum unwind diameter.
5. Engineered a compact clamping structure to securely mount the system onto the automated unwinder machine while considering spatial constraints, forklift movement, machine arms, sensors, and wiring accessibility.
6. Generated CAM toolpaths and G-code, and independently manufactured all mechanical components using a 3-axis CNC milling machine.
7. Installed and aligned the system on production lines, conducted validation trials, and optimized positioning to ensure accurate tab direction detection.
8. Collaborated closely with electrical and software teams to ensure integration, wiring and signal constraints, and refined the mechanical design based on cross-functional feedback.
9. Standardized and mass-produced the finalized design for deployment across 6 lines, ensuring consistency and reliability across different machine configurations.
10. Successfully reduced tab-direction errors, eliminated unnecessary rewinding processes, and significantly improved operator feedback and production efficiency.
Technologies Used
1. Design: SolidWorks
2. CAM: SolidWorks CAM
3. Manufacturing: Haas TM-2P (3-axis CNC Milling Machine)
4. Material: 6061 Aluminum
5. Testing: Assemble test was done in-house, properly validated, re-designed based on installation at factory production lines.
Key Highlights
- Designed and implemented a Tab Direction Vision System to eliminate feeding errors in EV battery unwinder operations.
- Integrated Keyence camera and illumination into a unified, adjustable mechanical structure adaptable to varying roller diameters (~620 mm).
- Engineered compact clamping system to fit within tight machine constraints without interfering with forklifts, sensors, or machine arms.
- Led full workflow, root cause analysis, concept development, CAD design, CAM programming, CNC manufacturing, installation, and validation.
- Collaborated with electrical and software teams to ensure proper mechanical vision system integration.
- Successfully deployed 6 systems currently running under 1-year customer-side validation across 6 production lines.
- Generated approximately $400K in revenue during initial deployment phase.
- Project scope exceeds $1M+ potential value if implemented across all factory production lines.
- Significantly reduced tab direction errors, eliminated rewinding operations, and improved operator awareness and process efficiency.
The Tab Direction Vision System was developed to detect the orientation of graphite web tabs (anode/cathode) on fully rolled EV battery cells (~620 mm diameter) before feeding into the automated unwinder machine. Incorrect tab direction previously led to reverse feeding and required complete rewinding, causing production delays.
A unified mechanical structure was designed to mount a Keyence camera and illumination system to accurately detect tab direction throughout the unwinding process. The system generates an alarm if the orientation is incorrect, enabling immediate operator correction.
Adjustable mechanisms were incorporated to accommodate minor roller diameter variations, and a compact clamping structure was engineered to fit within the machine’s tight spatial constraints. The system was successfully implemented across 12 production lines, significantly reducing tab-direction errors and eliminating unnecessary rewinding operations.
