SmartRay, the leading manufacturer of 3D sensors for quality inspection and metrology, has the complete solution for electric vehicle battery box and battery inspection, as the demand for cleaner, environmentally friendly transport increases globally.
As the most essential component of an electric vehicle, it is essential that the battery is tested and inspected for its size, any defects, and weld quality, all of which are directly related to the performance and safety of new energy vehicles.
Typically, there are three types of batteries used in EV: soft package power, square, and cylindrical. Each module has its own challenges in inspection to ensure safety and quality isn’t comprised.
Soft package power batteries are the single cells, and the smallest unit in the process. They must be inspected for their shape and size, and for surface defects. Inspection process challenges include differing colours, reflection from plastic film, and light absorption by black surfaces.
Square batteries offer a different inspection challenge, particularly during the weld inspection process, as the pole or connection piece is susceptible to contamination. Decomposition of pollutants can lead to welding explosion points forming, resulting in holes in the weld.
Like soft package battery cells, cylindrical cells are individual units which are typically used together in larger units. Product quality is essential, to ensure uniformity, structural integrity and efficient energy transfer.
In addition to the batteries themselves, the battery box often occupies the complete underside of an electric vehicle. The position of the battery box means that it makes a significant contribution to the structural integrity of the vehicle, and so must undergo 100% inspection of all welds.
There are typically more than 200 welds on an installed battery, consisting of a mix of different materials including high-alloy aluminium. These include laser sealing weld, floor plate welds, MIG welds, flat-milled welds, and friction stir welds.
To solve battery inspection challenges throughout the EV, automotive manufacturers are using the SmartRay JOSY weld inspection system, plus the high-definition, cutting-edge 3D ECCO sensors.
JOSY provides a complete solution to detect appearance defects in EV battery defects, including weld length, width, large/small pores, depression, asymmetry, burn-through, and undercut.
In addition, JOSY's inspection features for the battery box inspection include structural requirements (throat thickness and undercuts), spatters (risk of soft pack slit or misfit), and welding defects. Also, as the integrity of the weld seam is essential for leak tightness, another added benefit of using JOSY is that it highlights potential leaks on the battery.
ECCO 3D sensors combine the latest technologies with cutting-edge German engineering for high-quality inspection, guidance and measurement. Combining laser triangulation with innovative image formation technology, ECCO sensors created detailed 3D images that cut through the challenges of EV battery inspection.
Clare Rathsack, Business Unit Manager ECCO – Sensors, SmartRay, said: “Our JOSY weld inspection system and the industry-leading ECCO 3D sensors provide the complete solution for EV manufacturers, ensuring safety and quality, increasing efficiency and reducing manufacturing costs.”
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Source: https://www.smartray.com/