EV Battery Production Quality, Safety, and Reliability

The electric vehicle (EV) industry is growing rapidly around the world, driven by a variety of factors, including government regulations, consumer demand for environmentally friendly transportation, and technological advancements that have made EVs more practical and affordable.

The whole industry chain consists of semi- and semi/fully-automated production lines that require smarter tools to keep pace. Long-term quality, product reliability, and worker and facility safety are also top priorities.

FLIR offers the total solution for improving EV battery quality, reliability, and safety through its line of thermal imaging cameras, automation sensors, and Test & Measurement products.

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Battery Pack Quality and Safety Assurance

Identify potentially poor connections and underperforming cells and modules

Interconnections between cells, packs, and modules are welded and mechanically assembled connections; poor or loose connections will heat disproportionally. 

Thermal cameras provide real-time, non-invasive thermal imaging data at every step, helping manufacturers identify defects, optimize thermal management, and ensure EV batteries meet quality and safety standards at every production stage.

BMS Testing Support

Predictive maintenance fault components

Thermal cameras provide critical temperature data that empowers the battery management system (BMS) to make real-time decisions to maintain safe and efficient battery operation. This proactive approach to thermal management and fault detection helps maximize the performance, longevity, and safety of EV batteries.

Thermal Runaway Monitoring

Detect potentially dangerous conditions

Manufacturers partially or fully charge battery cells and modules during assembly, allowing the current to flow as they are connected. This results in increasing temperatures and current flow.

Unchecked thermal runaways can result in cataclysmic events. Thermal imaging can identify the thermal runaway conditions; when a thermal camera identifies an abnormally hot cell, the BMS can quickly isolate or cool the affected cell to prevent further escalation.

FLIR automated thermal cameras are a flexible, configurable solution to meet the needs of EV battery manufacturing. Fixed-mount models can identify a higher number of potentially loose connections and result in less end-of-line failures of the battery system. Integrating FLIR automated thermal cameras into production lines empowers manufacturers in several ways:

• Both visual and thermal monitoring
• Up to 640 × 480 (307,200 pixels) resolution thermal images
• Alarms anytime custom set temperature thresholds are crossed, so you never need to worry about missing a single defect.
• Easy to install and compatible with standard industrial protocols and video management systems including HMI, SCADA, and optional ONVIF S compatibility