BATTERY INSPECTION

Demand for batteries with ultra-thin layers, designed using stacked technology, continues to soar with the emergence of new products, ranging from electric vehicles to smartphones, to digital wearables, medical devices and drones.

However, the ultra-thin layers that enhance battery performance are susceptible to misalignment and damage. The spatial relationship between the layers must be checked to ensure they meet standard requirements and any unwanted particle residue identified. But these competing manufacturing priorities of safety and performance quality must be addressed within tight timeframes.

Varex Imaging offers innovative photon counting X-ray detectors for fast inspection speeds and distinctive, high-quality imaging. Choose the right combination of detector and tube, and system speed can be up to five times faster.

The DC-Thor photon counting X-ray detector can image at impressive speeds to generate volume data for exact quantitative offset measurements in the CT inspection of batteries.

The battery is tilted at specific angles so that the corners can be inspected. The DC-Thor images the battery corners and a section of the full volume is then reconstructed. The desired measurements are taken.

Photon counting X-ray detectors image so rapidly that a full battery scan of four corners, including handling time, can be achieved in only a few seconds.

Cylindrical batteries move continuously at 90 degrees past the DC-TDI line detector, while super-fast photon counting technology captures high quality X-ray images of the interior structure.

Direct conversion TDI X-ray imaging reveals tiny flaws at the anode-cathode ends, even at rapid production line speeds, because the line rates are very high and the X-rays are blur free. This is true for batteries of up to 200-250 layers, with layer thicknesses between 10-150 μm.

How is this achieved? With Varex imaging’s photon counting technology, the X-rays are converted to an electric signal without use of a scintillator. Spatial resolution and efficiency are improved and the image is free from afterglow effects.

The production line flows without interruption. Wear and tear on the machinery is reduced as there is no stop/start operation.

The DC-TDI line scanner removes the issue of image distortion related to the parallax effect.

When an object is X-rayed using a flat panel detector, the area to be imaged has to be positioned at 90 degrees to the source. If the area of interest were to travel to the edge of the cone beam, as would be the case on a moving inspection line, its relationship to the beam would change and negatively affect the image. It would be not possible to see the distances between anode and cathode ends.

The DC-TDI line scanner can continuously image the battery to create a clear, undistorted X-ray image of the anode and cathode ends. There is no need to stop the inspection line and flaws and damage can be easily identified.

Rapid inspection time – inspection line can move continuously for 2D

Highest possible inspection speed with the required field of view for 3D CT battery inspection

Product reputation – high image quality means defects reliably identified

Return on investment – photon counting detectors are durable and throughput is fast