CCD Real-time Weld Monitoring System 2026
Release time:
2026-02-02
In the 2026 manufacturing landscape for high-power prismatic cells (6kW and above), traditional "offline" sampling is increasingly viewed as a high-risk liability.
The End of "Post-Weld" Sampling
In the 2026 manufacturing landscape for high-power prismatic cells (6kW and above), traditional "offline" sampling is increasingly viewed as a high-risk liability. Huiyao Laser is advancing a 2026 technical roadmap in which every 6kW welding station can be equipped with a real-time CCD molten pool monitoring system with target sampling frequencies up to 10,000Hz. This technology is designed to capture molten pool instability within milliseconds, enabling rapid identification of spatter and blowhole risks and supporting First Pass Yield (FPY) levels approaching 99.9% in well-optimized lines.
The Physics of kHz Sampling: Why Legacy Systems Fail
Standard industrial cameras often operate at 30–60FPS, which is sufficient for pre-weld alignment but effectively "blind" during the actual fusion process. Huiyao Laser’s 2026 monitoring architecture is being developed around ultra-high-speed sensors capable of capturing data in the 10–20kHz range. At a welding speed of 200mm/s, a 1kHz system only takes one sample every 0.2mm, while a 10kHz system captures a data point every 0.02mm, providing an order of magnitude improvement in spatial resolution along the weld path. This higher resolution is critical because the "keyhole" of a 6kW fiber laser can fluctuate on microsecond timescales; when a violent contraction of the keyhole is detected, the system can flag a potential "cold weld" before the laser head moves to the next spot, enabling timely intervention rather than post-weld scrap.
Tech-Driven Feature Recognition: Process-is-Result
Huiyao Laser’s software does not just record video; it performs real-time metallurgical analysis. The integrated modules analyze the molten pool’s area, brightness, and spatter trajectory. If the spatter pattern deviates from the "Golden Template," the system automatically flags the module as NG (No-Go). This prevents defective modules from reaching the expensive End-of-Line (EOL) testing phase, where a failure would require the scrapping of an entire 314Ah pack.
Technical Comparison: CCD Monitoring vs. Legacy Inspection
| Feature | Huiyao 2026 Monitoring | Standard Vision System | Impact on Gigafactory ROI |
| Sampling Rate | 10,000-20,000Hz | <1,000Hz | Captures micro-spatter events |
| Detection Timing | Real-time (During Weld) | Post-weld (After Weld) | Zero-delay NG flagging |
| Defect Coverage | Blowholes, Spatter, Seam Drift | Surface scratches only | Reduces scrap rate by 15% |
Conclusion: Precision is the Ultimate Cost-Saver
In the world of high-speed automation, speed without control is just a faster way to produce scrap. At Huiyao Laser, we believe that the "Best Line" is the one that tells you exactly why a weld failed the moment it happens. By investing in 10kHz monitoring, you aren't just buying a camera; you are buying insurance for your entire production yield.
Ready to upgrade your welding quality?
Contactour Engineering team for more details
AUTHOR: The Huiyao Laser Engineering Team
A collective of solution architects and process engineers at Huiyao Laser, 100% dedicated to solving the core bottlenecks in EV and ESS battery manufacturing.
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