Zhengye ZY-XRay Automated Capacitor Internal Non-Destructive Inspection System
| Brand | Zhengye |
|---|---|
| Origin | Guangdong, China |
| Manufacturer Type | OEM/ODM Manufacturer |
| Country of Origin | China |
| Model | ZY-XRay |
| Pricing | Available Upon Request |
Overview
The Zhengye ZY-XRay Automated Capacitor Internal Non-Destructive Inspection System is a high-precision X-ray transmission imaging platform engineered specifically for inline and offline quality assurance in capacitor manufacturing and related electronic component production. Leveraging dual-stage microfocus X-ray source technology and digital image intensifier detection, the system generates high-contrast, real-time radiographic images with sub-micron spatial resolution—enabling non-invasive visualization of internal structural features including electrode layer alignment, dielectric voids, solder joint integrity, winding symmetry, and interlayer delamination. Unlike conventional 2D X-ray systems, the ZY-XRay integrates programmable motion control with geometric calibration algorithms to support quantitative 2.5D metrology, allowing thickness-corrected dimensional analysis across tilted or layered capacitor geometries without physical sectioning.
Key Features
- Automated Defect Classification Engine: Proprietary inspection software performs real-time pattern recognition using trained templates and threshold-based anomaly detection—classifying defects such as internal cracks, foreign particles, foil misalignment, and anode/cathode shorting with configurable pass/fail logic.
- 2.5D Metrology Suite: Supports calibrated linear distance, circle diameter, concentricity, point-to-center offset, and angular deviation measurements—all traceable to NIST-traceable reference standards and compliant with ISO/IEC 17025 measurement uncertainty guidelines.
- CNC Path Programming: Enables repeatable multi-point scanning sequences via teach-and-repeat functionality; stores up to 500 user-defined inspection routines with positional repeatability better than ±2 µm per axis.
- Intuitive Navigation Interface: Features a full-screen live image navigator with click-to-move targeting—reducing operator dependency and accelerating defect localization during high-volume screening.
- Three-Axis Precision Motion: X-ray tube and image intensifier move independently along X, Y, and Z axes via precision-ground ball screws and stepper motor drive; motion velocity is continuously adjustable from 0.1 mm/s to 10 mm/s with closed-loop position feedback.
- Digital Image Processing Pipeline: Supports DICOM, TIFF, BMP, and PNG formats; includes real-time contrast enhancement, noise suppression (non-local means filtering), edge sharpening, and dynamic range compression for optimal feature visibility.
Sample Compatibility & Compliance
The ZY-XRay accommodates standard capacitor form factors including radial leaded, SMD chip, tantalum, aluminum electrolytic, and supercapacitors ranging from 0402 to 35 mm diameter. Sample handling is optimized for automated integration into conveyor-linked production lines or manual loading in R&D labs. The system complies with IEC 61000-6-3 (EMC emissions), IEC 61000-6-2 (immunity), and GB/T 18801–2015 (Chinese national safety standard for industrial X-ray equipment). Radiation shielding meets GBZ 117–2020 requirements for occupational exposure limits (<1 µSv/h at 5 cm from housing surface). Software architecture supports audit trail logging and user access control aligned with GLP and GMP documentation practices.
Software & Data Management
The embedded inspection software runs on Windows IoT Enterprise and provides full data traceability: each acquired image is timestamped, tagged with operator ID, machine parameters (kV, µA, exposure time), and stage coordinates. Measurement results are exportable in CSV, XML, or PDF report formats compatible with MES and SPC platforms. Optional FDA 21 CFR Part 11 compliance package includes electronic signatures, role-based permissions, and immutable audit logs for regulated environments. Raw image archives are stored locally on RAID-1 SSD arrays with automatic daily backup scheduling.
Applications
- Root cause analysis of field-failure capacitors in automotive electronics and power supply units
- In-process verification of wound foil alignment in high-voltage film capacitors
- Post-reflow inspection of MLCC solder joint wetting and void content
- Qualification testing of new dielectric formulations under thermal cycling stress
- Comparative analysis of aging effects in electrolytic capacitors after life testing
- Failure mode mapping for DOE-driven reliability improvement programs
FAQ
Is the ZY-XRay certified for use in Class 1000 cleanroom environments?
Yes—the system’s enclosure meets ISO 14644-1 Class 7 (Class 10,000) particulate requirements; optional HEPA-filtered air purge kits enable upgrade to Class 6 operation.
Can the system integrate with existing factory automation protocols?
It supports Modbus TCP, OPC UA, and SECS/GEM interfaces for bidirectional communication with PLCs and MES systems.
What is the minimum detectable defect size under standard operating conditions?
At 90 kV and 150 µA, the system resolves features ≥15 µm in high-contrast metal structures; resolution varies with material density and geometry per ASTM E2737-20 guidelines.
Does the software support multi-language UI and report generation?
English and Simplified Chinese UI are standard; custom language packs (e.g., Japanese, Korean, German) are available upon request.
Is remote diagnostics and firmware update capability included?
Yes—secure TLS-encrypted remote access is enabled via integrated Ethernet port with configurable firewall rules and session time-out policies.
