New Drive Technologies

The transportation sector plays a crucial role in the energy transition. Here, alternative drive technologies make a significant contribution to achieving the emission targets that have been set. While approaches such as hydrogen-powered, CO2-neutral internal combustion engines have received little focus to date, electro-based drive technologies occupy an important position. In addition to batteries, fuel cells are being used in this area. SAC accompanies the transformation process from the classic combustion engine to new drive technologies together with its customers from the very beginning and is very familiar with the requirements and guidelines of the industry.

The highest quality demands are placed on key elements such as electrodes and bipolar plates. Since the highest standards apply to the production of functionally relevant parts, they must be reliably checked for critical defects.
By using SAC solutions for 100% inspection of components, production quality can be reliably ensured. With the help of image processing data, the production process can also be continuously improved and economically optimized.

Battery Cells and Fuel Cells

With Smart Cell Inspection, SAC offers image processing solutions for battery cell production. The sensor system is based on a further development of the patented trevista® technology and was specially designed for the inline inspection of coated electrodes.
Ready-made solution concepts are also available for the fuel cell / hydrogen cell sector, including inspection tasks on active elements such as bipolar half plates, bipolar plates, electrolyzers and passive elements such as hydrogen lines.

SAC offers image processing solutions for battery cell production (Smart Cell Inspection). The sensor system is based on a further development of our patented trevista® technology and was specially designed for inline testing of coated electrodes. Before the stacking and winding processes, the smallest particles and defects on the electrodes can be electrodes can be detected quickly and reliably.

At the same time the coating is inspected for irregularities such as coating defects, scratches and and kinks. The use of state-of-the-art AI technologies supports the precise localization and classification of defects; new defect types can be quickly learned and reliably detected.

Other relevant inspection areas/tasks:
  • Hairpin testing on stators
  • Battery housings, e.g. round cell, prismatic cell
  • Seal testing/weld testing
  • Pouch foil
  • Battery recycling

SAC offers efficient complete solutions for reliable inline surface inspection of bipolar plates. It makes sense to inspect the half-plates for coating defects already during the manufacturing process.

  • Sophisticated sensors and proven technology, perfectly tailored to 100% inspection of bipolar plates (top and bottom side)
  • Highest process reliability and avoidance of costly misproductions
  • The concept is suitable for all common plate formats and can be quickly adapted to new types


  • High volumes
  • Thin-walled stamped parts (sheet thicknesses from 70µm), very sensitive
  • Free-form surfaces
  • Defect-prone flank areas in the active zone
  • Glossy / reflective surfaces
  • Hybrid materials (uncoated, partial graphite coating, sealing materials)

Advantages of image processing systems:

For reasons of value creation, it makes sense to detect defects as early as possible in the production process and to initiate suitable corrective measures in the shortest possible time. In this way, the proportion of defects during end-of-line leak testing can be kept to a minimum.
The Cluster Fuel Cell BW is committed to expanding mobile and stationary hydrogen applications in Baden-Württemberg, with the aim of achieving the series production of the technology. As an important initiator it coordinates the transfer of knowledge between companies, research institutes, the public sector and associations.