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A fast retrofit inspection step for gigafactory lines already in production
Royma’s Quick CT adds a computed tomography (CT) inspection step to battery cell lines that are already in production, without redesigning the line. The manually loaded gantry CT station scans the four corners of each cell for electrode overhang, gaps, tab defects and foreign objects, at resolutions down to 28 µm and up to two cells per minute.
Quick CT is built for quality engineers who need 3D evidence from a running line now, not after the next line rebuild. It sits at-line or in the quality laboratory, takes cells from the line by hand and returns a measured result for each one to the plant’s MES.
A CT step that fits beside a running line
Adding a fully automatic inline CT system means conveyor integration, space in the line and a planned stop. Quick CT avoids all three. The operator loads a cell onto a dedicated handling table, and the station rotates each of the four corners into the X-ray beam in turn. The loading and unloading time is part of the stated cycle.
- Throughput of at least one cell per minute for cells up to 50 mm thick, and at least two cells per minute for stacked cells up to 25 mm thick, each including 15 s of manual loading and unloading
- 150 kV or 180 kV closed microfocus X-ray source
- Two-, three- or four-angle scanning, with scan angle and time configurable per product
- Interchangeable fixtures for fast changeover between cell sizes
- Results uploaded to the customer’s MES
The station is compatible with wound, stacked, cylindrical and can-type power battery cells. A granite detection frame isolates the scan from floor vibration, which keeps corner-to-corner measurements consistent across a shift.
“Quick CT gives a line that is already running the same four-corner overhang check that our inline systems perform, in a station the quality team can install next to the line,” says Gabor Szabo, Sales Director Europe, Royma Europe.
Measured results for each cell format
Quick CT measures overhang automatically. It locates the electrode tab endpoints and reports the overhang value for the inspected tab and the adjacent tab, together with positive-electrode, negative-electrode and overall alignment. The stated overhang detection accuracy is ±0.06 mm or better.
Scan time and resolution can be matched to the defect being screened. In Royma’s own test scans:
| Cell type and inspection task | Resolution | Scan time | Conditions |
|---|---|---|---|
| Prismatic cell, overhang (automatic) | 28 µm | 7 s | Cell thickness 29 mm |
| Wound cell, gap and overhang | 29 µm | 10 s | Cell thickness 35 mm |
| Cylindrical cell, overhang | 55 µm | 5 s | 160 kV |
| Bare cell, metal foreign objects (Cu, Al) | 100 µm | 1 s | 135 kV, cell thickness 12 mm |
| Bare cell, electrode folding and debris | 100 µm | 1 s | 135 kV, cell thickness 12 mm |
Tab welding, tab shape and current-collector-disc welds on cylindrical cells can also be inspected. The station shows weld pool depth, porosity and cold solder joints in the CT data for assessment by the operator.
Three layouts, from pilot line to large-format cells
Quick CT is available in three layouts. The single workstation takes cells from 80 to 600 mm long, up to 260 mm wide and 10 to 50 mm thick. The double workstation has the same footprint and feeds two positions for diagonal detection. For large-format cells, a double workstation for super-large cells takes cells up to 1000 mm long. Its A/B lead-chamber doors let the X-ray beam stay on while one position is unloaded and the other scans, so no time is lost ramping the voltage up between cells.
“Many plants want CT data on overhang and foreign objects before they commit to a full inline system. Quick CT lets them start with a measured result per cell and scale up later,” adds Szabo.
From at-line sampling to 100 % inline CT
Quick CT uses the same four-corner scan principle as the RMLCT7500 inline gantry CT for prismatic cells. A plant can therefore start with at-line CT on the lines that are already running, build up its defect data and acceptance limits, and move to 100 % inline inspection where the volume justifies it. More on CT for cells, modules and packs is on the batteries application page.
Test scans of your cells
Royma Europe offers test scans of your cells on Quick CT and an evaluation of the layout and throughput for your line. Contact Gabor Szabo, Sales Director Europe, Royma Europe, gabor_szabo@roymatek.eu, +49 15156503316 – www.roymatek.eu.
Royma Europe, Leibniz Universität Hannover – Institut für Produktentwicklung und Gerätebau, Gebäude 8143, An d. Universität 1, 30823 Garbsen, Germany.
