The Key to Reducing Scrap Rates​

Battery production demands stringent quality control to ensure safety, performance, and longevity. Exacom’s advanced X-ray inspection systems go beyond traditional AC-overhang checks, delivering real-time data on critical manufacturing parameters. By pinpointing and resolving quality issues at their source, manufacturers streamline processes, lower reject rates, and foster a more efficient, reliable production environment.

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Cylindrical Cell

Prismatic Cell (stacked)

Prismatic Cell (flat wound)

Pouch cell

AC-overhang measurements are provided for each individual adjacent AC pair on both the top and bottom side of the jelly roll or stack. The system outputs accurate x/y coordinate positions of electrode sheet-ends within both the local and global coordinate systems.

Go beyond AC Overhang inspection

  • Wound Cells
  • Stacked Cells

Total Electrode Length​

Measuring the length of each individual electrode sheet helps to analyse accuracy and performance of cutting /slitting process.

  • Cylindrical Cells
  • Prismatic Cells

Jelly Roll / Stack Position

Accurate measurement of the position and distance from the jelly roll/stack to the can. This analysis provides critical feedback on insertion and assembly, enabling immediate detection of any packaging issues.

  • Cylindrical Cells

Crimping Analysis

Measurement of various physical distances to evaluate crimping processes and to monitor tool wearing.Measurement of various physical distances to evaluate crimping processes and to monitor tool wearing

  • Wound Cells
  • Stacked Cells

Trending / Telescoping Analysis

Telescoping / trending analysis on jelly roll or stacks are vital to detect uneven overlay of the electrode sheets that otherwise might go undetected. Telescoping often indicates issues in the winding or assembly process.

  • Stacked Cells

Anode bending trajectory

Some cells can be subject to bent anode ends. Determining if the degree of bending and the trajectory is within tolerable limits is vital.

  • Prismatic Cells

Contamination detection

Cell contamination is a big risk for cell safety. Exacom offers 100% inline contamination inspection for detection of particles inside the cell.

  • All Cell Types

Realtime Data and Traceability

Exacom offers real-time data feedback on all inspection features, including full data traceabililty on cell level.

Process Improvement with Real-Time Data Analysis

Improvement starts with understanding your processes. Exacom`s advanced inspection system provides instant data on important manufacturing parameters at various possible quality gates. This information is utilized with real-time data analysis to drive continuous improvements on many of the manufacturing steps.

Increase Yield

  • Trend analysis for early warnings
  • Continuous improvement through process learning
  • Zero underkill, minimal overkill
  • Data mining to monitor equipment behavior
  • Full data traceability
  • Avoid recall costs with 100% save products

Shorten Ramp-Up

  • Eliminate guesswork during setup
  • Perform fast root cause analysis with traceable inspection data
  • Enhance equipment qualifications (e.g., stackers, winders)
  • Improve product design with inspection data for better manufacturability
  • NDT1: Inspection of jelly rolls or stacks after the winding/stacking step to catch quality variations early in the process and give instant feedback for winding stacking accuracy.
  • NDT2: Inspection after the mechanical assembly, verifying precise jelly roll/stack positioning inside the cans, assessing crimping accuracy as well as high accuracy AC-Overhang inspection.

These quality gates can also be combined to meet specific customer requirements.

PPM inspection speed
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Different inspected cell formats
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Machine installations worldwide
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Cells inspected
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Americas

John Psilopoulos

located in Atlanta (USA) john.psilopoulos@exacom.tech

Europe

Markus Möller

located in Hanover (Germany) markus.moeller@exacom.tech

Asia

Maximilian Wenzel

located in Singapore (Singapore) max.wenzel@exacom.tech