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Batteries are highly complex products. Small errors or deviations during production can lead to large quantities of scrap, impair the quality and service life of a battery, result in costly recalls and, in the worst case, jeopardize the health and safety of end users. Battery manufacturers therefore subject their products to strict quality control so they can intervene quickly in the event of a deviation. These quality checks are increasingly carried out by Automated Defect Recognition (ADR) algorithms, which automatically inspect the desired parts of a battery cell and save inspectors the time-consuming manual assessment. Waygate Technologies, a Baker Hughes business, recently guided a customer through this process – from integrating nondestructive testing into the production to the optimization of the software algorithm.

Electrification will drastically change our energy consumption in the coming years, and with it our everyday lives. Batteries will play a crucial role in this change. Global investment commitments in battery production amounted to USD 195 billion for 2022 and 2023[1]. The global battery storage capacity in the power sector doubled from 2022 to 2023, adding a total of 42 GW, while electric vehicle (EV) battery deployment rose by 40 percent in the same period[2]. These impressive figures and the increasing demand for batteries, fueled by consumer electronics, electric vehicles and electric energy storage systems (EES), present manufacturers with a major challenge: they must build new facilities and ramp up production as well as increase their productivity while ensuring consistently high quality. Concurrently, they must remain competitive by investing in technological advances such as higher energy density, shorter charge cycles and improved safety features - all while reducing costs and minimizing environmental impact. Nondestructive testing (NDT) solutions can speed up quality control processes and increase production throughput by enabling faster decision-making in many of these areas.

The power of industrial X-ray and computed tomography inspection

For battery manufacturers, NDT technologies such as industrial X-ray and computed tomography (CT) are particularly relevant as the properties of a workpiece, component, structure or system can be tested and analyzed with a view to characteristic deviations, defects and imperfections without damaging the original part. This delivers multiple benefits by providing unique insight into the internal structure and integrity of battery components.

The integration of these technologies into the design and production process facilitates the detection of defects at an early stage. This approach reduces the likelihood of costly recalls, increases overall product reliability, and opens the door for production process optimization.

For example, X-ray and CT inspections enable a comprehensive internal analysis of battery cells and packs. X-ray inspection serves to examine internal structures and detect defects such as cracks, cavities and misalignments without the need to disassemble the battery. CT scans go one step further, providing high-resolution 3D images that allow detailed analysis of internal geometry and composition, including electrodes, separators and housings. This level of detail is crucial for detecting potential problems that could affect battery performance and safety.

Another aspect that increasingly comes into play is the power of software and AI. As in other contexts and industries, AI is a disruptive force with an impact that is difficult to predict. Initial applications show that AI provides efficiency gains by helping to accelerate especially time-consuming steps in a process. Ideally, however, AI should not be seen as a replacement for human expertise, but rather as a powerful tool to enhance it. In the case of X-ray and CT inspections, intelligent and adaptive software can already automate measurements and generate reports, freeing up the inspector’s valuable time for other tasks. Inspectors do not need to review every single scan, but only the automated measurements and reports.

Overall, X-ray and CT inspections contribute to cost efficiency and environmental sustainability. By detecting defects early and ensuring that only flawless components are further processed, manufacturers can significantly reduce material waste and the cost of rework. Improved inspection capabilities also promote more sustainable manufacturing practices by optimizing the use of resources and minimizing the environmental impact of defective products. If the second life of a battery is also taken into account at this point, it can be stated that this technology can also support the reuse of used batteries and the recycling of battery raw materials.

Taking NDT inspection into account when planning a new production line

Setting up a manufacturing facility is difficult, and quality control is only a part of the manufacturing process. Battery manufacturers looking to implement NDT inspection using X-ray and CT must first identify the specific components and defects critical to their products, such as internal structural issues or electrode misalignment. Integrating inspection methods for these components and criteria into the production line requires careful consideration of workflow compatibility, including automation and data analysis. Compliance with industry standards is essential to ensure product certification and market acceptance. Additionally, manufacturers need to invest in training and developing expertise to operate the technology effectively and interpret the results. This comprehensive approach ensures that NDT methods enhance quality control without slowing down production.

As already described, faults in batteries can be of various kinds. One of the most critical is electrode misalignment. A battery typically consists of a cathode, an anode, and a separator that maintains a precise distance between them while allowing ions to flow. The correct distance between the anode and cathode is crucial for efficient ion exchange, preventing short circuits and ensuring optimal energy storage and release. Ensuring the correct distance in the overhang of the anode and cathode in the production process is extremely important as it directly impacts the battery’s performance, safety, and longevity. Misaligned electrodes can cause uneven current distribution, leading to hotspots within the battery, which increases the risk of thermal runaway—a dangerous condition that can result in fire or explosion. Additionally, misalignment can cause uneven wear on the electrodes, reducing the battery’s overall efficiency, capacity, and lifespan. Over time, this flaw can lead to internal short circuits, further compromising the battery’s reliability and safety, making it a significant concern for manufacturers.

Finding the right system for the task is an important and by far not trivial step, as each process is individual. Tailoring the system and the software to the specific needs of a customer is necessary to reach the desired results.

• Implementing X-ray and CT inspection for efficient quality control requires the right instrument
• ADR software solutions need to be set up in line with inspection demands and the skill-levels of operators to accelerate the process, save time and increase output
• Software optimization through AI training of algorithms with real scan results further speeds up decision making and improves results

Therefore, the partner company requires a deep understanding of battery manufacturing processes, advanced inspection systems, AI and machine learning software and consulting and maintenance services around the world.

Best practice example of an industry expert from the field

When an internationally operating battery manufacturer from Asia recently needed support setting up a new manufacturing site and overcoming challenges known to affect battery production quality and operational efficiency, the company sought expert advice from Waygate Technologies. Based on the analysis and recommendation of the expert team, the battery manufacturer decided to purchase two advanced nondestructive CT testing systems with superior high-resolution imaging, a reliable and flexible battery holder as well as an AI-based ADR software, providing detailed insights into the battery cells’ internal structure and allowing for precise identification of misalignment issues.

The ADR software solution can be customized and adapted to meet the specific needs of the client. In this instance, the overhang measurement ADR inspection utilized statistical analysis of anode and cathode alignments in a highly automated manner, significantly reducing the manual effort required to measure approximately 30 to 160 layers per cell individually. This approach accelerates quality control processes and enhances production efficiency by enabling quicker decision-making.

During implementation, the ADR software underwent extensive training with a large volume of scans to familiarize itself with diverse defect profiles and establish precise detection parameters. This phase was essential for ensuring the system's effective performance across various battery models and production batches. While inspection frameworks and procedures can be easily deployed, maximizing the potential of both hardware and software requires collaborative algorithm development and refinement with the customer. A sufficient amount of data for training is critical—the more input the software receives, the greater the automation and accuracy in defect recognition.

Installing the system adjacent to the production lines ensured consistency across sample inspections from each battery cell production line. The trainable ADR solution generates statistical data on electrode alignments with defined thresholds, allowing operators to quickly distinguish between acceptable and substandard quality using the software. The system is user-friendly, requiring minimal effort from the client and can be easily managed by both experienced operators and those with limited X-ray and CT training. The service provided included comprehensive on-site support, covering hardware implementation, software installation, and personnel training. The results were a seamless transition and immediate improvements in production line efficiency.

Process automation enables faster decision-making

The client not only improved production quality and reliability but also significantly decreased the manual inspection workload, resulting in higher throughput and lower operational costs. With the implementation of the new systems and integrated ADR solution, scanning time was reduced to just 1-2 minutes, with the capability to scan multiple cells simultaneously, effectively eliminating the “time per scan” bottleneck.

The success of this project highlights the company’s ability to provide advanced, customized solutions that address the specific challenges of battery manufacturing customers.