The customer challenge
Most EV battery pack and module manufacturers use battery cells with a certain level of charge when assembled, as it is generally believed that having a fully discharged lithium-ion battery is more dangerous than a fully charged one.
As individual battery modules are connected, current will begin to flow between the components. Often, this current flow creates an increase in the temperature of the cells or modules. As the temperature increases, the voltage within the system will decrease and result in an increase in current, further raising the temperature. This cycle of temperature rise is known as "thermal runaway" and, if undetected, can lead to battery damage and even fires within the facility.
The Battery Management System (BMS) is used to monitor temperatures and ensure battery health by checking for loose connections and internal short circuits. However, the BMS is generally not installed in the system until later in the assembly process. Therefore, monitoring of cell and module temperatures during initial assembly is done using portable IR temperature guns, which only provide temperature information over a small area, or not at all.
The solution
Thermal cameras provide battery system manufacturers with the ability to monitor the entire battery assembly for elevated temperatures and potentially dangerous situations due to thermal runaway. Since battery configurations can vary widely from assembly line to assembly line, the ability of thermal cameras to measure temperatures at thousands of different points helps ensure that a critical point is not missed.
FLIR A-Series Advanced Smart Sensor cameras can be installed to monitor each exhaust port of the battery assembly. Multiple regions of interest can be created using the online camera control interface with maximum temperature alarm thresholds set for each ROI. With EtherNet/IP, alarm signals can be sent to an industrial PLC for data logging and control of an alarm indicator light when a critical temperature threshold is exceeded. This configuration provides a historical record of temperature data, a visual indicator to workers if hazardous conditions arise, and eliminates the possibility of human error when using a portable temperature measuring device.
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The results
The use of A-Series cameras such as the A70 provides a significant improvement over individual operators using handheld temperature guns by increasing the repeatability and reliability of temperature measurements used to detect thermal runaway conditions. Enhanced, automated thermal monitoring provides a level of assurance that any potential hazards will be detected quickly, helping to reduce risks to both plant personnel and facilities.
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