DEVICE DELIVERS PINPOINT PRECISION

In modern battery cell production, accuracy isn’t optional — it’s the backbone of consistent quality. One of the most critical stages is the cell stacking process, where electrodes must be handled with absolute precision. To solve this challenge, SICK partnered with a leading research institute to develop a highly reliable height-measurement solution using the OD200 laser displacement sensor.

This collaboration proved exactly why the OD200 is becoming the go-to sensor for industries that demand precision, stability, and long-term reliability.

OD200: Compact Sensor, High-End Performance

The OD200 is a compact, short-range laser distance sensor equipped with a newly engineered measurement core. It features a high-speed receiver unit and an optimized optical system — a combination that pushes it far beyond typical market standards.

The customer summed it up perfectly:
“The OD200 offers the ruggedness and reliability of a high-end device, but in a miniature form. Its measurement stability and reproducible switching behavior outperform anything we’ve used before.”

This level of performance was exactly what was needed for the cell stacking system, where a vacuum gripper must stop at exactly the right position to lift the top electrode. Any deviation can disrupt the process. The OD200 solves this by precisely measuring the stack height in real time — consistently, accurately, and without extra calibration headaches.

PRECISE POINT MEASUREMENT WHERE IT MATTERS MOST

Initially, the team considered using a photoelectric retro-reflective sensor. But once they saw the OD200 in action, that idea was dropped fast.

The OD200 doesn't require a reflector and performs direct point measurement on the electrode surface — exactly where the gripper makes contact. This means:

• No issues with warped electrodes

• Accurate reads even when alignment angles change

• Faster integration and easier adjustments

As the customer put it:
“The OD200 measures exactly at the pick-up point, and it works reliably from almost any angle. That alone sets it apart.”

ULTRA-CONSISTENT RESULTS THANKS TO ADVANCED TRIANGULATION

Why are the measurements so stable and repeatable?
It all comes down to the OD200’s newly developed triangulation measurement core paired with powerful evaluation algorithms.

Michael Kiss, Strategic Product Manager at SICK, explains:
“The OD200 doesn't just solve the challenge in the cell stacking system. It can measure highly reflective, extremely dark, or uneven surfaces with impressive stability.”

This is game-changing in battery production environments where material surfaces often vary.

OPTICAL SYSTEM ENGINEERED FOR RELIABILITY

Another standout feature is the sensor’s optimized optical system. SICK redesigned the geometry and homogeneity of the light spot to ensure:

• Superior ambient light immunity

• Fewer false measurements

• Fewer missing signals

• Less downtime

• Lower setup and maintenance costs

• Higher overall productivity

In short: more efficiency with less trouble.

FAST INTEGRATION, ZERO DRAMA

Thanks to its miniature housing and standard connection interfaces, the OD200 was integrated into the cell stacking system quickly and with minimal configuration. Once installed, it started handling height measurements smoothly — no tweaking, no repeated recalibrations.

Since commissioning, the sensor has delivered consistent, reproducible measurements, proving itself as a reliable solution for demanding automation environments.

OD200: More Productivity Through Simple, Reliable Distance Measurement

The OD200 isn't just another sensor — it’s a precise, easy-to-integrate, low-maintenance tool built for industries where accuracy directly impacts output. For battery cell production and beyond, it stands out as a compact device delivering high-end performance where it truly counts.