How Is X-Ray Used In Battery Inspection?

X-Ray Inspection Can’t Be Understated. We Look At Specific Reasons Why Using X-Ray Battery Inspection Stands Above Other Inspection Methods

In modern times, many devices depend on lithium batteries as their storage of energy. Why? Because lithium batteries provide excellent energy density, have no effect on memory, and, more importantly, discharge less when not in use. With such benefits, the demand for these batteries has grown immensely.

The production of these batteries is a complex process. Typically, it’s a combination of mechanical engineering, chemical formulations, and sensitive electrical designs at cell and system levels. With such intricate processes, it’s only proper that reliable quality control systems are used to confirm the functions of the battery’s internal features.

Additionally, cells of high-performance batteries are so important that any defects can lead to catastrophic results. For years, x-ray has been used in battery inspection and product and quality control of battery cells. The battery x ray machine is an essential tool in detecting major faults inside the battery, including the latent ones that are usually difficult to detect using other inspection methods.

Why Is X-Ray Important in Battery Inspection?

The importance of x-ray inspection can’t be understated. Here, we look at the specific reasons why using x-ray battery inspection stands above other inspection methods, such as the optional method. To start with, x-ray inspection allows you to examine the internal electrode arrangement after assembly and determine the existence of any defects. Also, through x-ray battery inspection, you can identify any misaligned battery components, understand the cathode and anode layouts, and accurately measure the quality of electrical contacts.  To get a jelly roll, usually, lithium sheets are rolled together. Now, battery x-ray inspection helps you to identify any twists in the jelly roll or the presence of any nickel material. With x-ray inspection, you can also find out if the jelly rolls have the correct lengths and fitment.

In addition, x-ray inspection is crucial because it helps you detect misplaced internals and holes or voices in the jolly roll stacks. Because lithium batteries have high energy and generate heat, they’re typically encased in stainless steel to prevent leakages that can cause harm. To ensure the wall casing is of the right thickness, x-ray inspection is used. Should the wall be too thin, it can easily break and harm users.

Again, with an x-ray inspection system, you can accurately determine internal linear distances as well as electrode and anode alignments. With better alignments, the batteries can store high-density energy. Moving on, quality control relies on x-ray in battery inspection because it’s reliable and fast. With x-ray inspection, you get detailed results within a short time, allowing you to make spot-on decisions that can save your brand’s image. Again, being a non-destructive testing method, you can ensure that you won’t need to destroy the batteries under inspection, saving you the resources.

How Is X-Ray Used in Battery Inspection?

The battery x ray machine works pretty the same way as the Magnetic Resonance Imaging (MRI) scan at the doctor’s office. The main difference is that the battery x ray machine’s technology isn’t designed for human use in this case.

So, how does it work?  

Typically, scanning using the battery x ray machine can produce 2D, 3D, or 4D results. The 2D results are similar to what the MRI scan produces when one visits the doctor’s office with a broken bone. In this case, the internals of the sample are projected onto one image on top of each other.

In the 3D scan, the sample is placed on the manipulator and rotated 360 degrees while the machine takes thousands of images from different angles. Once the images are acquired, they’re reconstructed into a 3D model. Here, a part can be sliced through to indicate its internal components in a 3D format where even a minor or latent defect is detected.  In the 4D system, on the other hand, 3D images are acquired but with an added dimension of time. This way, you can actually see how the sample changes in 3D over time.  The X-ray principle is the same. The x-ray source sends the x-rays through the battery’s interior. This enables the machine to take the images of the sample battery, processes it using its inbuilt software, and sends them to the monitor where they are interpreted, and wrong products are isolated.

To get the results,

  1. Place the sample on the battery x ray machine’s manipulator.
  2. Close the door to complete the circuit (depending on the type of machine in use)
  3. Turn on the X-ray source
  4. Move or adjust the system into scanning positions
  5. The closer the sample is to the x-ray source, the higher the resolution its image will be
  6. Compile and optimize the images for a thorough analysis of the sample’s internal structure

Interestingly, the modern battery x ray machine can batch process the samples to save you from engaging in a laborious process of inspecting a single piece at a time. With lithium ion battery x-ray machines such as LX-1Y60-140,   you get to automate the inspection processes and utilize their imaging systems. To spice it up, such machines can work both online and offline.

Why Choose Uni X-Ray

Uni X-ray Technology Ltd, based in Shenzhen, China, has almost 20 years of focusing on the design, production, development, and R&D of industrial x-ray machines that are user-friendly and affordable.  With years of experience producing X-ray inspection technology and equipment, Uni X-Ray prides itself as a first-class quality solution provider to your manufacturing process. Uni X-Ray’s equipment and technology have endeared it to customers who have consistently ranked as their first choice for many years.

As a professionally tested and accredited X-ray machine company, Uni X-ray has continued to grow a list of dedicated elite enterprises. With such trust and loyalty, our commitment to customer experience remains our top priority. Additionally, Uni X-Ray has endeavored to recruit a highly professional and effective workforce that guarantees quality products at affordable prices. Uni X-Ray has enjoyed a competitive advantage against other companies that offer similar services by being innovative and constantly adding new and exciting features to the products.