Highly complex, sensitive, and costly components used in electric vehicles (EVs) such as battery cells demand modern test methods like CT to ensure safety and performance - like CT inspections supported by AI and deep learning.
Meeting electromobility inspection challenges with CT
As a quickly evolving industry branch, e-mobility demands advanced, future-proof inspection technology for its wide range of quality control applications. In collaboration with major automobile manufacturers, Comet Yxlon keeps researching and developing new solutions for efficient and reliable CT inspections. Applications include quality assurance of batteries, electric motors, e-mobility-specific castings, and other parts like tires, as they are exposed to higher stress and wear due to increased vehicle weight and torque.
Inspecting the battery – the heart of the electric car
In electric cars, the battery’s performance is critical to the reliability, range, and longevity of the entire vehicle. CT inspections with Comet Yxlon CT systems support both automobile and battery cell manufacturers with reliable, highly precise inspection data that e.g., help reduce scrap in mass production. Computed tomography is used to test raw materials for the battery cell, the individual cells, the cells packaged into a module, and the modules connected into a battery system or battery pack.
Efficient quality assurance for battery cells
One of the main challenges in cell production is the high scrap rate. Since this is a big cost issue, it is important to detect defective cells before further processing. Comet Yxlon CT inspection systems cover a wide range of techniques for non-destructive quality assurance and metrology applications. This includes overhang measurements of cathode/anode and the inspection for contamination and inclusions as the most important defect types of a battery cell.
Reliable CT inspection of battery modules
The very tight component and joining tolerances as well as the special requirements for contact welding make the stacking of battery cells to manufacture battery modules a challenging task. Computed tomography with Comet Yxlon systems delivers precise inspection results for the quality assessment of cell stack orientation, housing weld seams, cell connection weld seams, and tab welding. In addition, overhang measurement of cells already installed in modules is possible using Comet Yxlon laminography.
Testing battery systems and packs with CT
When the battery modules are assembled to form a battery system, they are connected to the system housing, usually a metal casting part, which serves for cooling. With Comet Yxlon CT inspection systems manufacturers can check this connection of the battery module to the housing, which has the function of a heat sink to make sure all components are fully functional.
Smart inspection with Battery Insights, powered by Dragonfly deep learning.
From segmentation to automated overhang measurements – Battery Insights, our new Dragonfly battery software package makes CT inspections of batteries as easy, fast, and efficient as never before. The innovative Dragonfly battery solution is based on an expert-trained deep learning (DL) model which gets customized to your exact requirements. The built-to-spec AI-powered package performs exact measurements and evaluations and delivers detailed reporting according to your individual needs. Eliminate operator bias from your battery inspections, benefit from a turnkey solution adapted to your specs, and unlock the power of smart automation with Dragonfly!
Powerful CT systems for scanning rotors and hairpin stators
The inspection of rotors and stators are the two most critical applications in quality testing of electric motors – specifically the determination of the attachment area and the total pore volume of welded joints of hairpins. Comet Yxlon took up the challenge and refined their FF35 CT with its excellent resolution and the at-line system UX20 with its 225kV MesoFocus tubes to supply foundries with precise quality inspection data.
Detecting casting defects in asynchronous motor rotors
When aluminum is cast into steel plates to produce a squirrel cage for an asynchronous motor, casting defects such as cavities and porosities can occur. For these dense components, Comet Yxlon developed their own CTScan 3 line detector array (LDA), with an unprecedented signal-to-noise ratio, a dynamic range, and a pixel pitch of 254 μm. The CTScan 3, which is used e.g., in the FF85 CT or the UX50, can provide high-quality images of the upper and lower connecting rings and the porosities of the aluminum inside the steel layers.
New components, new solutions: e-mobility-specific cast parts
In the innovative electromobility industry, novel components sometimes require new test methods to ensure functionality and safe operation. Just one example: aluminum cast housings for electric motors, battery systems, and inverters. Since they are equipped with integrated water cooling, leak tightness plays a crucial role in safety, taking into consideration the high currents and voltages of the engine system. X-ray inspections and CT scans can also be used to check if all channels are open to the cooling liquid.
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