Zhengye XG5010 Industrial X-ray Inspection System for Lithium-ion Battery Cell Quality Control

Overview

The Zhengye XG5010 Industrial X-ray Inspection System is a purpose-built non-destructive testing (NDT) platform engineered for high-precision internal structural analysis of lithium-ion battery cells and cylindrical/prismatic pouch cell assemblies. Leveraging digital radiography based on X-ray transmission physics, the system enables real-time visualization of internal features—including electrode alignment, weld integrity, separator wrinkling, foreign particle inclusion, void formation, and tab bonding defects—without physical disassembly. Designed specifically for QC/QA laboratories and inline production environments in battery manufacturing, the XG5010 integrates a high-stability microfocus X-ray source with configurable imaging detectors to deliver consistent geometric magnification and spatial resolution suitable for sub-100 µm defect detection. Its architecture adheres to ISO 17025 foundational principles for measurement traceability and supports integration into GLP-compliant workflows where audit-ready documentation is required.

Key Features

• Configurable Microfocus X-ray Source: Adjustable tube voltage (90–130 kV) and current (89–455 µA) enable optimization for varying cell thicknesses and material densities—from thin-film anodes/cathodes to aluminum/copper current collectors and steel casings.
• Multi-Modal Imaging Platform: Supports both image intensifier and flat-panel detector configurations, offering flexibility in FOV (Φ100 mm or 114.9 mm × 64.6 mm) and pixel resolution (1392 × 1040 up to 1536 × 864), ensuring compatibility with diverse cell geometries and inspection throughput requirements.
• 2.5D Metrology Suite: Built-in measurement algorithms support calibrated linear distance, circle diameter, concentricity, point-to-center offset, and edge-to-edge gap quantification—enabling quantitative evaluation of dimensional compliance per internal component layer.
• CNC Path Programming: Enables repeatable, operator-independent positioning sequences for small-batch or multi-site inspection routines; path memory retains coordinate sets, stage speed profiles, and exposure parameters for reproducible setup across shifts.
• Real-Time Navigation Interface: Large-scale preview window allows direct mouse-click targeting on live radiographic images, triggering automated stage movement and focal plane adjustment to the selected region-of-interest within <1.2 seconds.
• Radiation-Safe Enclosure: Fully interlocked cabinet meets IEC 61331-1 and national regulatory limits (≤1 µSv/hr at 5 cm from surface), incorporating lead-equivalent shielding, emergency stop circuitry, and door position sensors compliant with EN 60204-1.

Sample Compatibility & Compliance

The XG5010 accommodates standard cylindrical (18650, 21700, 26650), prismatic, and pouch-type Li-ion cells up to 450 mm × 410 mm in footprint and 5 kg in mass. Its open-stage design permits custom fixturing for jigs, thermal clamps, or electrochemical test leads during concurrent functional testing. All hardware and software components conform to electromagnetic compatibility (EMC) standards IEC 61000-6-3 and IEC 61000-6-4. The system supports documentation traceability aligned with ISO/IEC 17025 clause 7.7 (reporting results) and is compatible with FDA 21 CFR Part 11 requirements when deployed with validated user access controls and electronic signature modules.

Software & Data Management

The proprietary Zhengye VisionInsight™ software provides a unified interface for acquisition, annotation, measurement, and reporting. Radiographic images are saved in DICOM 3.0 or TIFF format with embedded metadata—including exposure parameters, stage coordinates, timestamp, and operator ID. Measurement logs export to CSV or Excel-compatible XML for statistical process control (SPC) integration. Audit trails record all user actions (e.g., parameter changes, pass/fail overrides, report generation) with tamper-evident timestamps. Optional API support enables bidirectional communication with MES platforms (e.g., Siemens Opcenter, Rockwell FactoryTalk) via RESTful endpoints or OPC UA.

Applications

• Electrode stacking misalignment verification in dry-room assembled cells
• Detection of metallic contaminants (e.g., Cu/Al shavings, stainless steel fragments) embedded in separator layers
• Quantitative assessment of weld seam continuity and penetration depth in tab-to-current-collector joints
• Void and delamination mapping in jelly-roll wound cores under static compression
• Post-cycling structural degradation analysis (e.g., anode swelling, cathode cracking) in failure mode studies
• Supplier qualification audits requiring objective, image-based evidence of internal build consistency

FAQ

Does the XG5010 support automated pass/fail classification based on user-defined thresholds?
Yes—the software includes rule-based decision logic that applies configurable tolerance bands to measured dimensions and grayscale intensity profiles, generating binary output with visual overlay indicators and summary reports.
Can the system be integrated into a cleanroom environment?
It is rated for Class 10,000 (ISO 7) environments; optional HEPA-filtered air purge kits and static-dissipative stage coatings are available upon request.
Is remote diagnostics and firmware update capability supported?
Yes—secure SSH-enabled remote access is available for authorized service engineers; over-the-air updates follow cryptographic signature validation per NIST SP 800-193 guidelines.
What calibration services are offered?
Zhengye provides annual traceable calibration using NIST-traceable step wedges and line-pair gauges; certificates include uncertainty budgets per ISO/IEC 17025 Annex A.3.
Are training and SOP development services included?
Standard commissioning includes 2-day on-site operator and administrator training; customized SOP templates aligned with ISO 13485 or IATF 16949 are available as optional deliverables.