How to Use X-ray to Inspect the Battery?

| Updated on February 28, 2024

The Importance of Battery in Modern Industry

Modern electrical appliances rely on battery power for their operations to provide energy. The batteries can be used as a sole provider or as backup energy sources. Additionally, batteries can store energy from wind or solar and discharge when needed most.

The importance of a battery in the modern industry can’t be understated. From house appliances to health instruments, military, firefighting, emergency operations, logistics to construction, the battery’s use is inevitable.

By 2019, the Freedonia Group, a research firm based in Cleveland, had projected that the demand for primary and secondary batteries would have risen by 7.7% yearly. However, the market for secondary batteries was projected to grow to 82% because of smartphones and tablets’ rise. This means that the need for batteries is ever on the rise, always needed for the operationalization of appliances used in our daily lives.

With changes in technology, the battery hasn’t been left behind. Over the years, there have been significant changes in the development of the storm. From the essential nickel-iron battery of 1899 to the more advanced lithium-ion battery of 1985, the battery industry has witnessed milestones that have reflected the ever-changing power needs of appliances.

How to Evaluate and Inspect Batteries

Like a living creature, it isn’t possible to measure the battery but rather use diagnostic methods to determine its health. To achieve this, some methods are used to evaluate and inspect batteries to determine their health and their effectiveness. However, no single test can be used to assess all the battery symptoms because there’ll always be those that go against the set protocols.

1. Quick-Sort Model Specific (QSMS)

This rapid-testing method checks the existing differences in resistive values during the battery assessment using Direct Current (DC) and Alternating Current (AC) methods.

While the algorithm isn’t complicated, it has a short test time. The only major challenge is creating test conditions such as deriving parameters from low, right, and average batteries.

2. Electrochemical Dynamic Response (EDR)

In this method, the flow of ions between the electrodes is measured. This is typically achieved when load pulses are applied, and the response time on attack and recovery is evaluated. Once the recovery times are noted, they are then compared with stored parameters relating to battery performance.

3. Electrochemical Impedance Spectroscopy (EIS)

This test aims to create a Nyquist plot when batteries with different or multiple frequencies are scanned. The recorded Nyquist information is superimposed on the electrochemical models, which helps in the estimation of State of Charge (SoC), capacity, and CCA non-invasively in a typical test-time of 15 seconds.

4. Battery Parser

This method establishes the exact State of Charge (SoC) using a specific patented algorithm. After that, colombs filling the existing battery space are counted, and the charge period is expected to be long enough to guarantee good results.

With the advanced artificial intelligence (AI) mechanism, the battery parser can produce accurate capacity results compared to the usual un-calibrated coulomb smart battery counter.

How to Use X-Ray to Inspect the Battery

Battery manufacturing is a complex process, and therefore quality control and safety testing are crucial in delivering a reliable product.

While simple electrical checks can identify faults, latent faults within the battery can be hazardous to the user if not detected, and corrected on time.

X-ray battery inspection provides the 100% in-line inspection that helps improve battery efficiency and guarantee its integrity. Among other things, this inspection method gives you the opportunity to:

  • understand the cathode and anode layout
  • measure internal linear distances accurately
  • measure the quality of electrical contacts
  • identify misaligned components
  • identify short circuits

But How is This Done?

First, roll the lithium or lead sheets together to create the jelly roll. Secondly, use Computer Tomography (CT) to check if the registration is twisted, the presence of nickel material, correct length, and fitment. The importance of this inspection is to identify if there are any misplaced internals or holes in the stacked layers.

To make it even better, apply industrial X-ray technology to determine the battery’s behavior when it’s depleted and when it isn’t. Besides, you can check the jelly roll’s concentricity, telescoping, and alignment.

X-ray inspection is also done on the battery’s casing, which prevents leaks that can cause harm. This means that you check the thickness of the case to ensure it is the required one.

Adam Green

With more than 3 years of experience as a software and tech writer on Adam has been writing articles, blogs, and featured stories centered around the software and tech niche since he graduated from Virginia Tech University. He writes savvy articles, tutorials, and reviews that explain difficult concepts to readers of all levels. His expertise includes software development, cybersecurity, artificial intelligence, and emerging technologies. Through simple and engaging writing, Adam constantly delivers useful insights that enable readers to feel at ease in the ever-changing technological scene.

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