Zhengye XRAY-BA Series Automated Non-Destructive Inspection System for Lithium-Ion Battery Cells
| Brand | Zhengye |
|---|---|
| Origin | Guangdong, China |
| Manufacturer Type | OEM/ODM Manufacturer |
| Country of Origin | China |
| Model | XRAY-BA Series |
| Pricing | Available Upon Request |
Overview
The Zhengye XRAY-BA Series is an industrial-grade, fully automated non-destructive inspection (NDI) system engineered specifically for the lithium-ion battery manufacturing and quality assurance ecosystem. It operates on the fundamental principle of X-ray transmission radiography: high-energy photons penetrate battery cells—typically pouch, cylindrical, or prismatic formats—and generate differential attenuation profiles based on internal material density, thickness, and structural integrity. The resulting real-time digital radiographs enable precise visualization of critical internal features including electrode alignment, tab weld integrity, separator wrinkles, foreign metallic particles, voids in jelly-roll winding, and anode/cathode delamination. Designed for integration into production lines or QC laboratories, the system delivers repeatable, operator-independent defect classification without physical contact or sample preparation—ensuring full compliance with non-invasive testing requirements defined in IEC 62619, UL 1642, and ISO 9001:2015-based quality management frameworks.
Key Features
- Automated Defect Recognition Engine: Proprietary measurement software performs real-time geometric analysis—including linear distance, circle diameter, concentricity assessment, and point-to-center offset—enabling quantitative 2.5D metrology directly from radiographic images.
- CNC Path Programming: Supports teach-and-repeat motion sequencing; users record inspection trajectories via manual jog or coordinate input, then execute identical multi-point scans across small-batch lots with sub-millimeter positional repeatability.
- Intelligent Navigation Interface: Features a high-resolution navigation map synchronized with the primary radiograph viewport; click any region in the overview image to trigger rapid, closed-loop motion control that repositions the X-ray source and detector assembly to the selected ROI within <1.5 seconds.
- Triaxial Precision Motion System: X-ray tube and image intensifier are independently mounted on three orthogonal axes (X/Y/Z), each driven by stepper motors coupled to precision ground ball screws and synchronous timing belts—ensuring smooth, low-vibration translation at programmable speeds from 0.1 to 10 mm/s.
- Fixed Sample Platform: Rigid, vibration-damped stage accommodates standard battery formats up to 300 × 200 × 80 mm (L×W×H); optional custom fixtures available for high-volume inline integration.
Sample Compatibility & Compliance
The XRAY-BA Series supports routine inspection of commercial lithium-ion cell formats—including 18650, 21700, 26650, 4680 cylindrical cells; LFP/NMC pouch cells up to 200 mm wide; and prismatic modules with integrated busbars. All imaging protocols adhere to ALARA (As Low As Reasonably Achievable) radiation safety principles. The system meets electromagnetic compatibility (EMC) Class A requirements per CISPR 11 and carries CE marking under the EU Machinery Directive 2006/42/EC and Low Voltage Directive 2014/35/EU. Radiation shielding complies with national standards GBZ 138–2002 and international guidance IAEA Safety Standards Series No. GSR Part 3.
Software & Data Management
The embedded inspection software runs on a Windows 10 IoT Enterprise platform and provides full audit trail functionality compliant with FDA 21 CFR Part 11 requirements—including electronic signatures, user role-based access control, immutable log files, and timestamped image metadata (DICOM-compliant headers). Radiographs are stored in lossless PNG or TIFF format with embedded measurement annotations; batch reports export automatically to CSV or PDF with pass/fail status, defect coordinates, and dimensional deviation metrics. Optional API integration supports MES/SCADA connectivity via OPC UA or RESTful endpoints for traceability in Industry 4.0 environments.
Applications
- Inline detection of electrode misalignment and tab mispositioning during cell assembly
- Verification of separator integrity and absence of micro-tears post-calendering
- Identification of metallic contaminants (e.g., Cu/Al shavings, stainless steel fragments) introduced during slurry mixing or coating
- Quantitative assessment of jelly-roll winding tension uniformity and core eccentricity
- Root-cause analysis of field-failure units through comparative radiographic morphology mapping
- Process validation for new cell designs prior to pilot-line ramp-up
FAQ
What radiation safety certifications does the XRAY-BA Series hold?
The system is certified to national radiation safety standards GBZ 138–2002 and conforms to IAEA SSG-46 guidelines for industrial X-ray equipment. Full shielding design limits leakage dose to <1 µSv/h at 5 cm from any surface.
Can the system interface with existing factory automation systems?
Yes—via optional OPC UA server module or HTTP-based REST API, enabling bidirectional communication with PLCs, MES, and QMS platforms.
Is remote diagnostics and software update support available?
All units include embedded Ethernet connectivity and support secure remote maintenance through TLS-encrypted VNC sessions, subject to customer network policy approval.
Does the software support multi-language UI and reporting?
English and Simplified Chinese interfaces are standard; additional languages (German, Japanese, Korean) available upon request with localized validation documentation.
What is the typical lead time for delivery and installation?
Standard configuration units ship within 8–10 weeks after order confirmation; on-site commissioning and IQ/OQ documentation support included as part of turnkey delivery.
