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Due to the energy transition and the growth of electromobility, the demand for lithium-ion batteries has increased in recent years. Great demands are being placed on the quality of battery cells and their electrochemical properties. Therefore, the understanding of interactions between products and processes and the implementation of quality management measures are essential factors that requires inline capable process monitoring. In battery cell lamination processes, a typical problem source of quality issues can be seen in missing or misaligned components (anodes, cathodes and separators). An automatic detection of missing or misaligned components, however, has not been established thus far. In this study, acoustic measurements to detect components in battery cell lamination were applied. Although the use of acoustic measurement methods for process monitoring has already proven its usefulness in various fields of application, it has not yet been applied to battery cell production. While laminating battery electrodes and separators, acoustic emissions were recorded. Signal analysis and machine learning techniques were used to acoustically distinguish the individual components that have been processed. This way, the detection of components with a balanced accuracy of up to 83% was possible, proving the feasibility of the concept as an inline capable monitoring system.

We investigated and compared various algorithms in machine learning for anomaly assessment with different feature analyses on ultrasonic signals recorded by sensor networks. The following methods were used and compared in anomaly detection modeling: hidden Markov models (HMM), support vector machines (SVM), isolation forest (IF), and reconstruction autoencoders (AEC). They were trained exclusively on sensor signals of the intact state of structures commonly used in various industries, like aerospace and automotive. The signals obtained on artificially introduced damage states were used for performance evaluation.Anomaly assessment was evaluated and compared using various classifiers and feature analysis methods. We introduced novel methodologies for two processes. The first was the dataset preparation with anomalies. The second was the detection and damage severity assessment utilizing the intact object state exclusively. The experiments proved that robust anomaly detection is practically feasible. We were able to train accurate classifiers which had a considerable safety margin. Precise quantitative analysis of damage severity will also be possible when calibration data become available during exploitation or by using expert knowledge.

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