EV battery inspection

Improve yield by 1 second CT scans

High-speed inline CT with MetalJet E1+

Reliable energy storage and efficient renewable energy production are key to a sustainable future. Fast-changing global vehicle fleets will require exponential growth in the number of battery cells produced. Excillum’s MetalJet X-ray sources enable full inline CT scanning capabilities with micrometer resolution, giving manufacturers the high-speed, high-resolution 3D imaging they need to increase the yield as well as ensure product safety and quality at the highest throughputs.

Inline X-ray computed tomography (CT) is a powerful inspection technique that can further reduce the risk of defects and recalls, compared with today’s 2D X-ray inspection techniques. Furthermore, when X-ray CT is integrated in cell assembly, defects can be automatically detected in real time to enable immediate corrective actions, thereby eliminating yield losses and quickening change control-type processes. However, to achieve the levels of inspection coverage, throughput and resolution necessary for high-volume battery production, a high-power X-ray source with a micrometer-sized X-ray spot is necessary. The Excillum MetalJet E1+ source makes this possible, achieving a full scan with micrometer resolution in just one second, or less.

Anode-cathode overhang

An internal feature to be inspected during manufacturing of a battery is the anode overhang. The anode should be dimensioned to overlap the cathode. To produce this with repeatability puts high demands on the manufacturing and process precisions. To inspect this with precision in prismatic battery cells, X-ray CT is a pre-requisite. Furthermore, to have a 3D model of each produced battery cell can be very helpful for forensics in case a battery cell fails in the field – in order to minimize a recall to an as small volume as possible.

The following images, of pouch, prismatic and cylindrical cells, were captured in just one second, or less, by an Excillum MetalJet E1+ X-ray source, making CT highly suitable for inline and end-of-line inspection during high-volume manufacturing.

1 second X-ray CT of an EV battery cell

In this video, you’ll see an example of how we achieve a full CT-scan with micrometer resolution of an EV battery cell in only 1 second, using our MetalJet E1+, a high-performance detector from Direct Conversion (Thor FX20.256 CdTe) and a high-speed, high-precision rotation stage.

A game-changing solution for EV battery cell production

Together with VCbattery, we are bringing high-speed 3D CT inline inspection for EV battery cell manufacturers. The video below shows our game-changing solution to how the EV battery industry can achieve greater efficiency, accuracy, and safety in the production of battery cells.

Interested in a demonstration?

Together with our partner VCbattery, we have a demonstrator where you can experience first-hand the capabilities of our high-speed 3D CT inline inspection system.

Are you a manufacturer of EV battery cells or electric vehicles? Book a demo with us!

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About the Excillum MetalJet E1+

High speed full inline CT scanning by MetalJet technology

The MetalJet E1+ delivers 17 times higher X-ray brightness compared to conventional microfocus X-ray sources, which enables fast inline CT inspection in battery cell manufacturing.

Excillum’s MetalJet X-ray tubes feature a liquid-metal jet anode, eliminating traditional X-ray source power limitations caused by anode damage. This innovation supports higher electron-beam power, resulting​ in significantly increased X-ray brightness.​

Built for 24/7 continuous performance

The MetalJet E1+ is designed for high-throughput, 100% duty-cycle operation with up to once-per-year preventive maintenance cycles. This eliminates the need for frequent filament changes as required by traditional tubes.

Sub-µm positional stability

Although running at a high thermal load of 1000 W, the MetalJet E1+ maintains a positional stability of below 1 µm during continuous long-term operation.

Features and benefits

  • Extreme microfocus source power​
  • Superior spot quality​
  • Minimal maintenance​
  • LaB6 long-life cathode​
  • Very stable X-ray emission and spot position​
  • No external cooling water requirement
  • User-friendly Graphical User Interface
  • Controlled through GUI or TCP/IP protocol
  • Operated remotely from any computer

Technical specifications

Target material1

Liquid metal alloy

Min. focal spot size

< 10 μm

Target type

Liquid jet

Emission stability3

< 1%

Voltage

30-160 kV

Position stability3

< 1 μm

Power2

0-1000 W

Min. focus-object distance

22.5mm

Max current

6.25 mA

Beam angle

20°

1) The room temperature liquid metal alloys supplied for the MetalJet source consist mainly of gallium, indium and tin. They have low reactivity and low toxicity but should be handled according to their safety data sheets and local regulations.
2) The actual power used is dependent on spot-size and voltage. However, maximum output power of the 160 kV high-voltage generators is 3000 W software limited to 1000 W.
3) Standard deviation.

Powered by partnerships

Excillum’s sources are an integral part of system development for some of the most trusted names in X-ray instrumentation. Together, we work intensely to put the benefits of MetalJet and NanoTube sources into the hands of users everywhere.

Contact us

Please contact us for further discussions or to book a demo. 

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