Laser

Ultrasonics

Xarion Battery Inspection

XARION´s Battery cell ultrasound inspection for the battery industry

XARION’s LEA (Laser-Excited Acoustics) ultrasound NDT for batteries detects quality issues in battery cells by utilizing non-contact ultrasound. In contrast to conventional ultrasonic testing, XARION does not use any coupling agent or gel.

This process identifies properties that may have a significant impact on battery performance and lifespan. Given the widespread use of batteries in applications like electric vehicles, renewable energy systems, and electronic devices, it is crucial to ensure their safety, reliability, and performance by identifying and addressing any potential issues that may arise.

Electrolyte distribution and electrolyte wetting inspection

The full-surface and homogeneous wetting of battery cells with electrolyte fluid is a crucial factor for their lifetime and reliability. XARION’s LEA ultrasonic technology enables the non-contact detection of electrolyte distribution and electrolyte wetting status within prismatic and pouch cells. The principle is shown in the image below: a short laser pulse creates an ultrasound wave in the battery. The ultrasound wave travels through the cell, with sites that lack or have insufficient electrolyte wetting conducting less or no ultrasound, while sites that are well wetted conduct ultrasound. XARION’s Optical Microphone detects the ultrasound leaving the battery cell and XARION’s software creates an image that lets you see inside the battery, showing the degree of distribution or wetting of the electrolyte.

Foil-to-tab welding and bus bar welding

Electrode foils are welded to a current-collector tab. This is crucial for the cell’s stability and safety and is done quickly and economically with ultrasonic welding machines. XARION’s Optical Microphone, in conjunction with the WeldAlyzer data analysis software, enables fast and reliable in-line process monitoring of this important battery production step.

Bus bars are used for permanent cell-to-cell and module-to-module connections. Laser-welding is often the method of choice, since it is a fast and economical way of connecting bus bars. XARION’s non-contact ultrasonic testing method allows inspection of the quality of these welds, and avoids failure after delivery.

Pouch cell sealing

Instead of a hard metal casing, pouch cells rely on a polymer-coated aluminum foil casing. Errors in the sealing of these foils cause leakage of electrolyte fluid, which needs to be avoided at all times. XARION inspection technology can automatically detect even the smallest leakages and optimize the output of your production line.

Thermal paste detection

To avoid overheating, all the battery cells contained in a battery pack or module need to be thermally connected to the outer housing. This is achieved by filling any gaps with thermal paste. XARION’s single-sided inspection technique allows for quick inspection to see whether all the gaps are filled or not, even in large battery modules.

Features

  • See inside the battery cell!
  • Battery cell NDT without contact or coupling liquid
  • Fully automated and high-speed battery cell inspection
  • Inspection of the electrolyte wetting status of your battery cells with 0.2 mm resolution
  • Ensuring perfect sealing of pouch cells
  • Detecting void regions in thermal paste behind module housing walls
  • Monitoring ultrasonic foil-to-tab welds in real-time

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XARION Battery Inspection Brochure

Xarion Ultrasonics Testing of Composite Materials

XARION‘s unique Laser-Excited Acoustics (LEA) technology enables contact-free ultrasonic testing of composite parts or adhesive layers with high resolution. Enabling a reliable detection of internal defects or delamination. The LEA technology can easily be integrated into robotic or scanner systems and is also available as LEAsys, a turnkey scanner solution.

The combination of ultrasound excitation by laser pulses and XARION’s proprietary ultrasound detector achieves the best of two worlds: it matches today’s standard liquid-coupled UT in sensitivity and resolution, while it does not require water or coupling gel. The compact LEA probe is fully fiber-coupled and has been designed for robotic inspection from the start. Its robustness against misalignment and surface variations ensures high signal-to-noise ratio over the whole inspection area, minimizing costly manual retesting.

Features

  • No water, no coupling gel needed
  • Sub-mm resolution of internal defects and delaminations
  • High-speed inspection with up to 2000 mm/s
  • Robust against misalignment in stand-off and angle
  • Single-sided and through-transmission arrangement possible
  • Compatible with monolithic parts and honeycomb sandwich structures

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XARION LEAsys Brochure

XARION Non-Destructive Testing Brochure

Xarion Spot Weld Inspection

XARION’s approach to spot weld inspection is radically different from other testing methods, since it works without physical contact to the car body. This allows a robot-controlled inspection of spot-welds in the automotive industry and a reliable distinction between OK and NOK welds.

This method has been designed for robotic inspection from the start, in contrast to manual methods that have been tweaked for robotic use. This brings a fundamental advantage: it works with an otherwise unachievable tolerance to misalignment of several millimeters. Hence, XARION’s spot weld inspection system is a natural match for industrial robots in a real-life production environment. Compared to state-of-the-art manual inspection, this fully automated high-speed solution reduces inspection costs by a factor of ten.

Features

  • No coupling liquid necessary
  • Reduction of inspection costs by a factor of 10
  • Inspection time: 5 seconds per spot weld
  • Throughput: 8000 spot welds per day
  • Measurement accuracy: better than 300 µm
  • Tolerance to misalignment: 5 mm
  • Robust against surface inhomogeneity

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XARION Spot Weld Inspection Brochure

Xarion Semiconductor Inspection

XARION‘s unique laser-based technology enables the ultrasonic inspection of semiconductor components without any coupling liquid. The sensor technology can be easily integrated into a high-volume production line or is available as a stand-alone desktop tool. XARION’s inspection tool saves costs for offline analysis and ensures inspection of 100% of the components, e.g. packaged devices for the automotive sector.

Two test methods are offered: a high-speed, non-contact imaging mode, and an ultrafast single-shot evaluation mode for up to 1000 components per second. Both modes allow for the nondestructive detection of delaminations and other internal defects. XARION’s technology increases productivity in failure analysis and reliability in production.

Features

  • Compact and highly versatile desktop tool or fully automated inline inspection tool
  • 100% documented safety for your customer
  • Unique non-contact sensor technology without liquid coupling media
  • No interference with other production steps
  • High-speed imaging mode with up to 10 000 imaging points per second
  • Single-shot inspection mode for up to 1000 samples per second
  • Combination with offline non-contact imaging of defective components for further analysis possible

Xarion ETA600 Ultra

The membrane-free Eta600 Ultra Optical Microphone represents the latest development in XARION’s sensor technology. With a frequency bandwidth ranging from 50 kHz to 4 MHz for air-coupled ultrasonic measurements and the highest sensitivity within the Eta product line, this sensor proves to be optimal for use in ultrasonic testing applications that require high resolution. In conjunction with XARION’s technology for laser-based ultrasound excitation, the sensor is deployed in applications such as non-destructive testing (NDT) of semiconductor components and composite materials, used in the aerospace industry.

Features

  • Membrane-free Optical microphone
  • Frequency range 50 kHz–4 MHz
  • Self-noise: 3.5 µPa (BW: 1 Hz, measured @ 500 kHz)
  • Max. sound pressure for THD < 3%: 20 Pa
  • Dynamic range: 95 dB

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XARION ETA600 Datasheet

Xarion ETA450 Ultra

The membrane-free Eta450 Ultra Optical Microphone is designed as a contact-free ultrasound sensor for non-destructive testing (NDT) of various materials. With a frequency bandwidth spanning from 50 kHz to 2 MHz, this sensor is a perfect match for use with broadband laser-ultrasound excitation. Its compact size and non-contact nature make it exceptionally well-suited for ultrasonic testing of composite materials, spot welds, and adhesive joints.

Features

  • Membrane-free Optical Microphone
  • Frequency range 50 kHz–2 MHz
  • Self-noise: 5 µPa (BW: 1 Hz, measured @ 500 kHz)
  • Max. sound pressure for THD < 3%: 40 Pa
  • Dynamic range: 100 dB

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XARION ETA450 Datasheet

Xarion ETA250 Ultra

XARION’s Eta250 Ultra membrane-free optical microphone allows coverage of the acoustic frequency bandwidth from 10 Hz to 1MHz with a single sensor head and is ideally suited for process monitoring. It was specially designed for applications with low self-noise requirements.

Features

  • Membrane-free optical microphone
  • Low self-noise level
  • Frequency range: 10 Hz–1 MHz (acoustics and ultrasound)
  • Dynamic range: 50–150 dB (A) SPL

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XARION ETA250 Datasheet

Xarion ETA100 Ultra

XARION’s Eta100 Ultra membrane-free optical microphone allows coverage of the acoustic frequency bandwidth from 10 Hz to 1MHz with a single sensor head.
The system was also designed for very high sound pressure levels up to 180 dB (A) SPL.

Features

  • Membrane-free optical microphone
  • For very high sound pressure levels
  • Frequency range: 10 Hz–1 MHz (acoustics and ultrasonics)
  • Dynamic range: 80–180 dB (A) SPL

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XARION ETA100 Datasheet

Xarion ETA450 Ultra Array

A sensor array containing 8 optical microphones in a single head. The array is suitable for high-speed, non-contact ultrasound NDT. The array is best combined with XARION’s line-profile excitation laser unit for ultrasound signal generation.

Features

  • Membrane-free optical microphone linear array
  • Compact sensor head
  • Eight channels with 2 mm pitch
  • Custom channel number and pitch available on request

Xarion ETA250 L Ultra

XARION’s Eta250 L Ultra is a highly sensitive, membrane-free optical hydrophone. Designed to detect faint signals in the frequency range from 10 Hz up to 2 MHz with a millimetre-sized sensor head, it offers unique capabilities for ultrasound metrology in liquids. Using patented technology, the Eta250 L Ultra is immune to electromagnetic interference and features excellent long-term stability.

Besides high-frequency sonar for military and civil applications, it is also the perfect match for medical ultrasound and photoacoustics.

Features

  • Highly sensitive, fiber-coupled optical hydrophone
  • Detection of small pressure amplitudes with a millimetre-sized sensor head
  • Immunity to electromagnetic interference (EMI)

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ETA250 L Ultra Datasheet

Xarion ETA100 L Ultra

XARION’s Eta100 L Ultra is a robust, long-lasting optical hydrophone designed for ultrasound sensing in rugged environments. Using patented technology, the Eta100 L Ultra sensor is immune to electromagnetic interference, damage or de-calibration from high pressure amplitudes and allows measurements at elevated temperatures up to 100°C. Covering a 50 kHz to 10 MHz frequency range and pressure amplitudes in the kPa to MPa range, it offers highly versatile ultrasound detection in liquids within a small form factor.

This makes the Eta100 L Ultra the perfect ultrasound sensor for military and civil applications in high electromagnetic fields, or for the characterization of ultrasound transducers with high sound pressures that could potentially destroy other hydrophones.

Features

  • Suitable for temperatures up to 100°C, resilient to decalibration by high pressure amplitudes
  • High versatility through small footprint and 10 MHz measurement bandwidth
  • Fiber-coupled optical hydrophone
  • Immunity to electromagnetic interference

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ETA100 L Ultra Datasheet

Xarion Thermoacoustic Emitter

The Thermoacoustic Emitter (TAE) is a unique, air-coupled, ultrasound source for ultrasonic excitation over a broad frequency range. The transducer generates a Dirac-shaped, spatially-focused, ultrasound pulse via a fast electronic discharge. The TAE operates without moving parts and hence is an excellent match with XARION’s optical microphone. Applications for the transducer include non-contact ultrasound evaluation (NDE) of materials, and acoustic spectroscopy.

Features

  • Pulse width: 1 µs (FWHM)
  • Frequency range: 10 kHz-1 MHz
  • Peak pressure: 1000 Pa (154 dB rel. 20 µPa)
  • Focal spot size: 1 mm
  • Focal distance: 20 or 30 mm
  • Generation for air-coupled ultrasound testing and acoustic spectroscopy

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Xarion Thermoacoustic Emitter Datasheet

Xarion LEAsys

LEAsys is the perfect tool for R&D laboratories or research institutions engaged in the nondestructive testing of composites, metals, and adhesive joints. The integrated scanner solution combines the innovative LEA technology with a high-resolution x-y scanner and real-time data analysis software. It enables contact-free high-resolution scans without the need of water or a coupling gel.

The ultrasound signal is generated with XARION’s laser-based excitation technology. XARION’s proprietary optical microphone detects the acoustic signal transmitted or reflected from the sample. Through-transmission as well as single-sided (pitch-catch) measurements can be performed, allowing the detection of internal defects, delamination or porosity in a contact-free manner. For time-sensitive applications, XARION also offers an eight-channel microphone array system.

Hardware Features

  • Excitation laser with 100, 400, or 10,000 Hz pulse repetition rate or thermoacoustic excitation
  • Detector: Eta450 Ultra optical microphone with 2 MHz bandwidth
  • Minimum step size: 10 µm
  • Scan range: 530 x 500 mm or 530 x 1000 mm
  • Data acquisition: 14-bit resolution, 50 MHz sampling rate

Software Features

  • GUI for control and data analysis
  • Display of A-, B-, and C-scans (real-time)
  • Minimum step size: 10 µm
  • FFT, spectral analysis (F-scan)
  • Easy export of resulting image in BMP format
  • Raw data export in CSV format

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Xarion LEAsys Brochure