The global new energy industry—spanning lithium-ion batteries for electric vehicles (EVs) and energy storage, photovoltaic (PV) modules for solar power, and hydrogen fuel cells for clean transportation—has become a cornerstone of the low-carbon transition. As production scales expand and technologies advance, the industry faces unprecedented demands for precision: battery electrode coatings require ±2μm thickness uniformity to avoid thermal runaway, PV cell micro-cracks as small as 10μm can cut power output by 5%, and hydrogen fuel cell bipolar plates need ±0.01mm channel precision for efficient gas flow. Conventional fixed-focus industrial lenses struggle to keep up—frequent refocusing slows production, and limited adaptability fails to address diverse component sizes (from 1m-wide PV panels to 0.1mm-thin battery separators).
At the forefront of solving these challenges is the liquid lens—a revolutionary optical component that adjusts focus in milliseconds via voltage or pressure, eliminating mechanical moving parts. Paired with specialized industrial lenses (telecentric, macro, line-scan), it redefines efficiency and accuracy in new energy manufacturing. A trusted provider of these cutting-edge solutions is Yixian Sensor Technology Co., Ltd. (Yixian Sensor), whose Liquid Lens Series and complementary industrial lenses are engineered to meet the unique needs of new energy production. From real-time battery electrode inspection to PV wafer crack detection, Yixian’s products deliver high speed, flexibility, and reliability. For detailed specifications, application cases, and technical support, visit Yixian Sensor’s official product page: https://www.yixiansensor.com/en_US/products.
Liquid lenses’ dynamic focus capability and rapid response make them indispensable for new energy’s most demanding inspection tasks. Below are their three core applications, paired with Yixian Sensor’s tailored solutions.
Lithium-ion batteries (LIBs) are the backbone of EVs and grid energy storage, and their quality directly impacts safety and performance. Key inspection challenges include electrode coating uniformity, cell tab welding integrity, and separator defect detection—all of which require adaptability to uneven surfaces and high-speed scanning.
• Electrode Coating Thickness Measurement: Battery anodes and cathodes are coated on metal foils (copper for anodes, aluminum for cathodes) with a thickness of 50–200μm. Even a 2μm deviation can cause capacity loss or local overheating. Yixian Sensor’s High-Resolution Liquid Lens (available on its product page) adjusts focus in <10ms to measure coating thickness across warped foil edges or uneven surfaces. Paired with Yixian’s macro lens, it captures 20,000 data points per second, ensuring uniformity across 1m-wide electrode rolls. This prevents hotspots that could lead to battery fires.
• Cell Tab Welding Inspection: Battery cell tabs (thin copper/aluminum strips, 0.1–0.3mm thick) are welded to current collectors. Cold joints, burrs, or incomplete welds increase internal resistance, causing energy waste or overheating. Yixian’s Liquid Lens + Polarized Lens Combination suppresses glare from reflective metal tabs while dynamically focusing on weld seams of varying heights. It detects burrs as small as 5μm and cold joints with 99.9% accuracy, critical for EV battery packs that undergo thousands of charge-discharge cycles.
• Separator Defect Detection: Battery separators (10–20μm-thick porous films) prevent direct contact between electrodes. Pinholes or tears as small as 2μm can cause internal short circuits. Yixian’s Liquid Lens + Line-Scan Lens System scans separator rolls at 5m/min, adjusting focus in real time to resolve tiny defects. Its high-speed performance matches separator production lines, reducing waste and ensuring battery safety.
PV modules must maintain high efficiency for 25+ years, so inspection of silicon wafers, cell interconnections, and glass coatings is critical. Liquid lenses excel here by adapting to large FOVs and warped surfaces, ensuring no defects are missed.
• Silicon Wafer Crack Detection: PV silicon wafers (166–210mm in size, 160–180μm thick) are prone to micro-cracks during cutting or handling. Even a 10μm crack can reduce module power output by 3–5%. Yixian Sensor’s Liquid Lens + Telecentric Lens captures uniform images of entire wafers in one scan, dynamically focusing on warped edges to detect micro-cracks. Its low distortion (<0.05%) eliminates false positives, a common issue with fixed-focus lenses that struggle with edge defects.
• Cell String Soldering Inspection: PV cells are connected into strings via solder ribbons (1–2mm wide). Misaligned ribbons or cold solder joints create resistance, lowering current flow. Yixian’s High-Speed Liquid Lens adjusts focus in 5ms to inspect solder joints across cells with slight thickness variations (±5μm). It detects ribbon misalignment of ±0.1mm and cold joints, ensuring modules meet IEC 61215 efficiency standards.
• Anti-Reflective (AR) Coating Measurement: PV glass AR coatings (50–100nm thick) maximize light absorption. Thickness variations of ±5nm can reduce light transmittance by 2%. Yixian’s Liquid Lens + Spectral Imaging Module measures coating thickness at 1,000 points per cm², adjusting focus to account for glass surface irregularities. This ensures uniform coating, preventing unnecessary energy loss.
Hydrogen fuel cells—key for heavy-duty EVs and stationary power—rely on precise bipolar plates and membrane-electrode assemblies (MEAs). Liquid lenses’ ability to focus on 3D structures and conductive materials addresses critical inspection needs.
• Bipolar Plate Flow Field Inspection: Bipolar plates (made of stainless steel or graphite) have micro-channels (0.5–2mm wide, 0.3–1mm deep) for hydrogen/air distribution. Blockages or uneven channels reduce cell efficiency by 10–15%. Yixian Sensor’s Ultra-High-Resolution Liquid Lens focuses on 3D flow field structures, measuring channel depth and width with ±0.01mm precision. Its compatibility with conductive metals eliminates reflection-induced errors, ensuring gas flows evenly.
• MEA Thickness Measurement: The MEA (a sandwich of membrane, catalyst, and gas diffusion layers) has a total thickness of 50–100μm, with ±2μm tolerance. A thickened catalyst layer can cause hydrogen crossover, reducing cell life. Yixian’s Liquid Lens + Confocal Imaging System adjusts focus to measure each MEA layer individually, detecting thickness variations and ensuring fuel cell durability.
Beyond liquid lenses, other specialized industrial lenses play vital roles in new energy manufacturing. Yixian Sensor offers a full portfolio to cover every stage:
• Telecentric Lenses: Yixian’s Low-Distortion Telecentric Lens is used for PV module dimensional measurement (e.g., frame alignment, glass size) with ±0.05mm accuracy. It eliminates perspective errors, ensuring modules fit standard mounting structures and meet installation requirements.
• Macro Lenses: For EV battery cell voltage testing, Yixian’s High-Contrast Macro Lens captures clear images of tiny cell terminals (0.5×0.5mm), enabling accurate probe alignment. This prevents test errors that could lead to incorrect cell grading.
• Line-Scan Lenses: Yixian’s Wide-FOV Line-Scan Lens scans entire energy storage battery packs (1×2m size) for external defects (scratches, dents) at 10m/min. It ensures packs meet aesthetic and structural standards for residential or commercial energy storage systems.
New energy manufacturing’s unique demands—high speed, 3D structure compatibility, and harsh environments (e.g., battery drying ovens, PV glass cutting dust)—require lenses with exceptional performance. Yixian’s solutions stand out with three key advantages:
• Dynamic Efficiency: Liquid lenses reduce refocusing time by 90% compared to mechanical lenses, critical for high-volume lines (e.g., 10,000 battery cells per hour). This cuts production bottlenecks and boosts throughput.
• Environmental Durability: All lenses undergo temperature cycling (-40°C to 85°C) and IP67 dust/waterproof testing. Anti-corrosion coatings protect against hydrogen fuel cell humidity, while anti-static treatments (10^6–10^9 Ω) suit battery cleanrooms.
• Cost Savings: Liquid lenses eliminate the need for multiple fixed-focus lenses, reducing tooling costs by 30%. Yixian’s integrated systems (lens + camera + software) simplify deployment, cutting integration time by 50%.
As new energy evolves toward higher efficiency (e.g., 4680 EV batteries, perovskite PV cells), Yixian Sensor is advancing its lens portfolio:
• AI-Driven Adaptability: Integration of AI algorithms to enable auto-focus and parameter adjustment based on component type (e.g., battery electrode → PV wafer), reducing manual intervention.
• Perovskite PV Inspection: Development of liquid lenses with sub-nanometer resolution to measure ultra-thin perovskite films (1–5μm thick), supporting next-gen PV modules with 30%+ efficiency.
• Battery Safety Monitoring: Future systems will combine liquid lenses with thermal imaging to detect early-stage battery cell overheating, enhancing safety in EVs and energy storage.
Industrial lenses—especially liquid lenses—are essential for unlocking precision and efficiency in the new energy industry. Yixian Sensor, via https://www.yixiansensor.com/en_US/products, delivers tailored solutions that address the unique challenges of battery, PV, and fuel cell manufacturing. From dynamic focus for battery electrodes to high-precision flow field measurement for fuel cells, Yixian’s lenses empower manufacturers to improve yield, ensure safety, and accelerate the global shift to clean energy. As the new energy sector grows, partnering with a specialized provider like Yixian Sensor will remain key to staying competitive. The future of sustainable energy relies on optical precision—and Yixian’s lenses are leading the way.
