Stable laser welding processes through real-time monitoring

The European industry is working at full speed to set up its own production chains for e-vehicle batteries: more than 20 gigafactories are currently being planned. One of the most important processes here is laser welding to precisely join lightweight materials and small components. For quality and costs to be right, however, the processes must function stably. Deviations and errors must be detected and eliminated immediately before rejects are produced and the line has to be stopped.

This is exactly what the VIRO WSM inspection system does: it monitors the welding process in real time and reports anomalies outside the tolerances. As a result, NOK parts can be immediately identified and automatically reworked; the causes of defects can be quickly found and eliminated. The system has been used for years by leading companies in battery production, primarily in Asia, and has recently also become available for European manufacturers.

Automatic weld seam testing for safety-relevant vehicle parts

Defective welds can get vehicle manufacturers into serious trouble. In the worst case, lawsuits and recalls are imminent, which can cost millions of dollars and a good reputation. Therefore, zero-defect tolerance applies to safety-relevant parts. No part with a defective weld, for example on axles, bodywork or batteries, may be delivered. However, manual testing is expensive and error-prone.

This is why OEMs and Tier 1 suppliers have been relying on VIRO WSI for decades: an optical inspection system that inspects every single weld seam fully automatically and detects all relevant defects from 0.1 millimeter with 100% reliability. Since the inspection takes place directly in the welding line, it is possible to quickly intervene in the upstream welding process. This consistently reduces defects, optimizes processes, and avoids downtime, rework, and rejects.

Optical inspection of battery boxes for e-vehicles

One area of application for VIRO WSI that is currently in particularly high demand is the automated quality inspection of battery trays - the central element in the body of electric vehicles. At this component, the system can not only inspect the more than 100 individual weld seams. In the same way, it detects weld spatter or other contaminants on surfaces, as well as missing or ill-fitting screw connections. The commissioning of VIRO WSI is comparatively quick - one of the reasons for the system's success.

Optimize welding lines with software support 

Guaranteeing high quality and zero defects while working economically: these two goals are difficult to reconcile. The solution: permanent process optimization. However, manufacturers are often slow to make progress with the processes involved in welding and weld seam testing. Many optimization tasks are performed manually, based on experience and trials.

With the Weldloop software, optimization can be accelerated significantly. It allows the data from the weld seam inspection to be linked with the data from the welding process, evaluated and visually displayed. Causes of deviations and defects can thus be found and eliminated quickly, with minimal downtime. Conducting long-term analyses, further optimization potential can be uncovered.


All three solutions support vehicle manufacturers and suppliers in setting up efficient, highly automated production. They enable defect-free products that can hold their own in global competition. Learn more about VITRONIC's innovations at the SCHWEISSEN & SCHNEIDEN trade show, September 11-15, 2023 in Essen, Germany. Visit us in hall 3 at booth 3D49. Please feel free to arrange a personal meeting in advance.


VITRONIC is the world's leading innovation driver for machine vision, enabling its customers to master the challenges of tomorrow.

The global group of companies develops forward-looking solutions in the form of specialized products and software for image-based quality inspection, identification and process optimization, which find application in the growth sectors of automation and traffic engineering.

VITRONIC solutions make an important contribution to helping shape a safe and sustainable world. The existing limits of what is economically feasible are constantly being questioned in order to achieve the highest quality and productivity, for example in the production of automotive and pharmaceutical companies. Worldwide, Auto-ID solutions in logistics centers and at cargo airports, take over the reliable and efficient recording of shipments and thus ensure a transparent flow of goods.

In the transport sector, VITRONIC offers leading technology for increased safety on the roads, for optimizing traffic flow and for recording road usage.

Open and honest dealings with our customers form the foundation for jointly exploiting technological and process potential to the full. Joint success forms the basis of long-term cooperation with companies such as B. Braun, BMW, Daimler, DHL, UPS, Fresenius and Sanofi as well as with public clients.

Since its foundation in 1984, VITRONIC has been growing continuously for 40 years. The current annual turnover (2023) is above 240 million EUR and the company is currently represented on five continents in over 80 countries with approximately 1,400 employees. Since 2024 the company is part of ITIS Holding, leveraging the strengths of both entities, creating a strong end-to-end ITS and automation provider.

Development and production of VITRONIC systems are located at the company headquarters in Wiesbaden. VITRONIC subsidiaries span across all continents, including North and South America, Europe, Asia, Africa, and Oceania. Additionally, a global network of sales and service partners ensures localized support for international customers.

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Megatrends such as globalization, mobility, urbanization, connectivity and health awareness require courage and a pioneering spirit. As innovation drivers, we enable our partners to master the challenges of tomorrow: We go further where others stop and bring new ideas into the here and now.