I. Production Dilemma Behind 5% Rejection Rate
With the rapid development of the new energy vehicle industry, BYD's blade battery factory has a daily production capacity of 13,000 units but was plagued by a 5% rejection rate. Investigation revealed that 100μm-level large particles were the core source of contamination, and the traditional monitoring system of the ISO Class 8 (100,000-class) clean workshop had fatal shortcomings.
II. Technological Breakthrough of Customized Monitoring System
KQET developed a real-time online particle monitoring system for BYD, filling the technical gap through two core innovations:
1. Online Monitoring Technology Breakthrough
Innovatively added a 100μm exclusive monitoring channel, using optical focusing technology to enhance scattering light signal intensity, locking large particle detection accuracy to the 100μm level. Combined with 28.3 L/min high flow sampling technology, the sample volume per unit time increased by 30% compared to traditional equipment, effectively eliminating monitoring blind spots.
2. Intelligent Monitoring Network Construction
The system integrates 8-channel synchronous monitoring capabilities, covering the full particle size range from 0.3μm to 100μm. The 7-inch touch screen displays concentration curves of each particle size in real time, supporting WIFI data transmission to the production management system for remote monitoring via mobile phones.
III. Significant Results of Engineering Application
Verification data from the first production line showed that the system reduced the fluctuation amplitude of 100μm particle concentration by 60%, and the battery product yield increased from 95% to 98.2%. Based on the annual capacity of a single production line, it is estimated to reduce quality losses by 31 million RMB annually.
Based on the success of the first phase, BYD and KQET initiated large-scale deployment, with the remaining 79 production lines to be connected to the monitoring network in stages. Once fully operational, it is expected to avoid 250 million RMB in production losses annually.
IV. Industry Inspiration: Precision Monitoring Reconstructs Quality Cost Logic
This case reveals a new industrial management paradigm where "precision monitoring is productivity": shifting from traditional post-event detection to real-time process control. By accurately capturing 100μm particles, a preventive quality control system is established.