CGN Dasheng NDT Helps Power Batteries Pass Quality Tests Smoothly

News of new energy vehicle fires occasionally surfaces, and the culprit is almost always the power battery. To fundamentally address this industry-wide problem, the mandatory national safety standard "Safety Requirements for Traction Battery of Electric Vehicles" will officially take effect on July 1, 2026, ushering in the "strictest examination" the battery industry has ever faced. Facing high-standard testing requirements, CGN Dasheng has deployed its "full suite of non-destructive testing capabilities," leveraging precise and comprehensive non-destructive flaw detection technologies to help the industry deliver a high-standard "safety answer sheet."

The internal structure of a power battery is wound layer upon layer, resembling a Swiss roll. During production, subtle defects such as electrode foil wrinkles, metal debris contamination, and misalignment between positive and negative electrodes may occur. These "minor issues" can evolve into overheating, swelling, or even fire during subsequent charge-discharge cycles.

AI-generated illustration of battery overheating and fire

In the past, identifying defects required disassembling the battery and peeling it apart layer by layer, much like performing surgery. Not only did disassembly destroy the original state and risk losing critical evidence, but what was even more frustrating was that sometimes the root cause could not be found even after complete disassembly. Today, non-destructive testing technology is overcoming this challenge. Acting like a tailor-made "medical X-ray machine" for batteries, it can penetrate the casing without cutting open the cell, revealing internal wrinkles, foreign objects, and weld porosity at a glance. This technology can not only "diagnose the disease" but also "trace the cause." For "ailing" batteries with issues such as capacity degradation or increased internal resistance, it can accurately reconstruct their original factory state, helping technicians pinpoint the root cause of failures and prevent the recurrence of similar defects.

Three Solutions, Each with Its Own Strengths

Targeting different stages of battery production and application scenarios, CGN Dasheng offers three differentiated inspection solutions, covering the complete demand chain of "sampling inspection," "precision inspection," and "full inspection."

① AI Intelligent X-ray Inspection

Equipped with micro-focus X-ray equipment and a self-developed AI defect recognition system, it automatically captures and labels internal wrinkles and foreign object defects in cells, with a miss rate below 0.01% and recognition accuracy exceeding 95%. Simple to operate with moderate investment costs, it is perfectly suited for routine batch sampling inspection on factory floors, achieving both cost control and quality improvement.

Micro-focus X-ray equipment

Inspection result of negative electrode wrinkling in power battery cells

② High-Precision 3D CT Inspection

Leveraging sparse-angle scanning and professional reconstruction algorithms, a single battery can be imaged in 3D within 50 seconds, revealing even the finest electrode structures at a glance. Ideal for new product R&D, process debugging, and failure review, it is the go-to choice for high-precision defect analysis in the laboratory.

③ High-Speed Online CT Inspection

Utilizing electron beam scanning micro-focus X-ray source technology, the inspection time per battery is compressed to within 16 seconds, with no mechanical movement throughout the process, completely eliminating imaging artifacts. Image clarity is maximized, perfectly matching the rhythm of automated production lines, enabling 100% online full inspection of batteries in large volumes and directly boosting mass production efficiency.

Rapid scan reconstruction result of a battery

Quality inspection has become a rigid requirement, and we safeguard the safety red line. Now, with the implementation of stringent national standards, power battery quality inspection has become a core process in industry production. CGN Dasheng's full suite of non-destructive testing solutions achieves a leapfrog upgrade in battery defect detection—from "invisible" to "clearly visible," and from "destructive disassembly" to "non-destructive 3D imaging"—comprehensively guarding the safety red line of power batteries.