Overview
In EV battery manufacturing, production environments are often harsh, space-constrained, and highly sensitive to disruption. AI-driven inspection and robotic handling must operate continuously to ensure safety and product quality. By deploying Premio’s super-rugged SFF edge AI computer alongside Premio’s industrial-grade supercapacitor UPS, the manufacturer achieved reliable performance, uninterrupted processing, and safe system control across its battery production line.
Challenges
- Need for a high-performance CPU capable of handling real-time AI inspection and robotic control simultaneously
- Requirement for a super-rugged, UL-certified system that can withstand harsh battery manufacturing environments
- Compact form factor needed to fit inside control cabinets and robotic enclosures
- Need for rich automation-ready I/O connectivity to interface with sensors, cameras, and robotic systems
- Risk of system interruption during power fluctuations and requirement for safe shutdown to prevent hazardous conditions, data loss, and equipment damage
Solution
- Premio’s Super-Rugged Small Form Factor Computer (RCO-3000-RPL Series)
- Intel 13th Gen Core i9 processor for real-time AI inspection and robotic control
- Fanless, cableless design with MIL-STD-810H shock and vibration resistance for harsh environments
- Compact small form factor for flexible cabinet and robotic deployment
- 4x COM and 16-bit DIO for precise robotics control and trigger-based inspection workflows
- 1x EDGEBoost I/O bracket for expansion, configured with 4x M12 PoE ports for high-speed industrial cameras
- UL 61010-certified industrial design for safe deployment inside control cabinets and compliance with safety standards
- Premio’s ECO-1000 Series with 16x supercapacitors for instantaneous backup power and controlled shutdown
Benefits
- Reliable AI inspection and robotics with proven industrial-grade systems
- Safe and continuous operations backed by integrated power protection
- Faster deployment and long-term support with U.S.-based engineering
Company Overview
A U.S.-based manufacturer specializes in lithium-ion battery production for electric vehicles and energy storage systems. The company focuses on delivering high-performance, safety-critical products through advanced automation and precision engineering. As domestic demand for electrification grows, it continues to invest in resilient and scalable smart manufacturing technologies.
The Challenges
High-Performance Processing for AI and Robotics
Battery cell inspection requires real-time image processing alongside robotic control, placing heavy demands on system performance. In safety-critical environments, processing delays can lead to incorrect inspection results or mistimed robotic actions, increasing the risk of mishandling sensitive battery cells.
Harsh Manufacturing Environment
Battery production environments expose systems to dust, vibration, and temperature fluctuations. These conditions can cause system instability or failure, directly increasing the risk of operational disruption and safety hazards.
Space-Constrained Deployment
Control cabinets and robotic enclosures offer limited integration space. Systems must be compact without compromising performance or thermal stability, as poor integration can introduce heat and wiring risks that impact safety.
Need for Automation-Ready Connectivity
AI inspection systems require seamless connectivity with cameras, sensors, and robotic controllers for synchronized operation. Any latency or communication failure can result in incorrect actions and unsafe handling of battery cells.
Power Instability and Safety Risks
Power fluctuations can interrupt inspection and robotic operations at critical moments. Sudden outages may leave systems mid-process, creating hazardous conditions, risking equipment damage, and causing data loss without proper backup and shutdown control.
Elevated Safety and Compliance Requirements
EV battery manufacturing involves energy-dense materials requiring strict safety and regulatory compliance. Systems deployed inside control cabinets must meet proper certifications to ensure safe operation and avoid regulatory and operational risks.
The Solution
RCO-3000-RPL: Edge AI Processing and System Control
High-Performance Edge AI Processing
Powered by an Intel 13th Gen Core i9 processor, the system enables real-time AI inspection alongside robotic control with low latency. The platform also supports Intel Core Series 2 processors (Bartlett Lake) for future scalability. This ensures accurate defect detection and precise robotic timing, reducing the risk of misclassification and unsafe handling.
Rugged Design for Harsh Environments
The fanless and cableless architecture minimizes failure points while withstanding dust, vibration, and temperature fluctuations. This ensures stable operation in demanding battery manufacturing environments and reduces the risk of unexpected system failure.
Compact Integration in Control Cabinets
The small form factor allows deployment inside control cabinets and robotic enclosures without compromising performance. Its wide DC input range supports flexible industrial integration while maintaining safe thermal and electrical operation in confined spaces.
Automation-Ready and Scalable I/O
With 4x COM ports and 16-bit DIO, the system enables precise communication with PLCs and robotic controllers for trigger-based workflows. Through the EDGEBoost I/O bracket, the system is expanded with the EBIO-4ETH-POE-M12 module, adding 4x M12 PoE ports for high-speed industrial cameras. This ensures synchronized inspection and robotic actuation with minimal latency.
Certified for Safe Industrial Deployment
The UL 61010-certified design ensures compliance with safety standards required for systems installed inside control cabinets. This enables safe electrical operation in EV battery manufacturing environments and supports regulatory requirements.
ECO-1000: Power Continuity and Safety Control
The ECO-1000 Series provides instantaneous backup power using 16 industrial-grade supercapacitors, delivering up to 200W output to the RCO-3000-RPL Series through a direct 12V or 24V DC connection. This ensures continuous system operation during power fluctuations without interruption. Equipped with three configurable smart modes, it enables controlled shutdown during extended outages, allowing inspection data to be safely stored and robotic operations to complete without creating hazardous conditions. With up to 500,000 lifecycles and a 10-year lifespan, it offers significantly greater durability than traditional battery-based UPS systems, reducing maintenance requirements. Its DC power compatibility and plug-and-play design enable seamless integration with the RCO-3000-RPL Series, ensuring stable and reliable power delivery in industrial automation environments.
Deployment Architecture
The Benefits
Proven Reliability for Industrial AI Deployment
Premio’s industrial-grade edge platform delivers stable AI inspection and robotic control in harsh environments. This eliminates the risks of using non-industrial systems in continuous manufacturing operations.
Safer Operations with Integrated Power Protection
The RCO-3000-RPL Series combined with the ECO-1000 Series EDGEBoost EnergyPack UPS ensures uninterrupted operation during power fluctuations and controlled shutdown during outages. This prevents hazardous conditions, protects equipment, and preserves critical data.
Faster Deployment with Local Engineering Support
With Los Angeles-based engineering support, the manufacturer benefits from faster deployment and responsive integration assistance. Combined with long lifecycle components, this reduces downtime and simplifies long-term maintenance.
Conclusion
By integrating edge AI computing with intelligent power backup, the manufacturer achieved a safe and resilient battery production line. The solution ensures continuous inspection, protects robotic operations, and preserves critical data during power disruptions. This deployment highlights how reliability and safety are essential to scaling EV battery manufacturing.