Battery and control board inspection

Global efforts to reduce CO2 emissions are creating a trend toward the electrification of vehicles. Electric vehicles (EVs) have large-capacity lithium-ion batteries (LiBs) and control boards, which are increasingly expected to be in demand worldwide. Since these key parts are also involved in the safety of vehicles, there is a growing focus on the use of X-ray inspection to ensure quality or to improve product yield.

 

Hamamatsu Photonics has a lineup of products suitable for X-ray non-destructive testing that contributes to the development and manufacture of in-vehicle batteries and control boards.

X-ray for non-destructive inspection

X-rays are electromagnetic waves with a very short wavelength, high energy, and have the characteristic of penetrating through matter.

 

When X-rays penetrate a material, attenuation occurs depending on the density and thickness of the target material. X-ray imaging translates this feature with an X-ray detector, which displays the attenuation rate difference of the object as contrast in the image. 

Non-destructive inspection on a conveyor belt

During an X-ray non-destructive inspection, you may combine X-ray sources and detectors depending on the application. In general, 1D detectors are used for the in-line inspection of continuously transported objects, while 2D detectors are used for an off-line 3D inspection and structural analysis.

 

Based on our extended experience in manufacturing a wide range of X-ray sources and detectors, we respond to our customers' needs by offering the most advanced solutions. 

Product features 

Discover our wide range of X-ray sources and detectors necessary for X-ray imaging.

X-ray sources

Microfocus X-ray (MFX) source

Microfocus X-ray sources have an X-ray focal spot size in the order of micrometers, enabling the acquisition of high-definition X-ray images with minimal blur even when imaging at high geometric magnifications.

Conventional X-ray source vs. MFX 

There is a clear difference in the high-resolution image obtained from our MFX solution. 

X-ray detectors

X-ray TDI cameras

The X-ray TDI camera uses a special CCD readout technology called TDI (time delay integration) to achieve both high-resolution and high-sensitivity images for high-speed inspection. Compared to two-dimensional sensors, the X-ray TDI camera captures the object being transported vertically, acquiring images without distortion in the transport direction.

Inspection by 2D sensor 

An image from a 2D detector will be distorted along the length of the sample, due to the geometric set-up. Samples have to be slowed or stopped in order to be imaged. Dimensional measurements cannot be implemented correctly. 

Inspection by linear sensor 

A more precise image is realized as X-ray is radiated vertically to the object. Linear X-ray detectors allow for continuous movement of the sample. Dimensional measurements can therefore be implemented correctly.  

Application examples

Electrode distance inspection on cylindrical LiBs

Distance inspection of spirally wound LiBs with distinct thickness

The C12300-121 acquires images at a maximum scanning speed of 50 kHz. It is ideal for high-speed inspection of cylindrical LiBs where objects are carried in continuously. 

The C12300-323 is built for capturing images using tube voltages up to a maximum of 180 kV. So even spirally wound LiBs, which are typically thicker and require high X-ray energy transmission to image the position of the electrodes and their layers, are able to be inspected precisely. 

Electrode distance inspection on laminated LiBs

Inspection of contaminants on cathode sheets

The C12300 series acquires distortion-free images in the carrying direction. The positions of the electrodes in laminated LiBs can be precisely inspected by scanning them in their lamination direction. High-resolution, high-speed inspection can be achieved by combining an X-ray TDI camera with a microfocus X-ray source. 

The C12300-461B has high sensitivity at the low tube voltage region and its sensors are configured in a staggered arrangement. Even though minute contaminants on thin objects can be detected, it is ideal for the inspection of sheet materials such as cathodes, anodes, and separators on LiBs. 

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