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, particularly in battery production inspection.

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, specifically designed for battery thermal inspection.

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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. 

The interconnections between cells, packs, and modules are critical, as poor or loose connections can lead to uneven heating. Our 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 play a vital role in predictive maintenance by providing 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

During the assembly process, manufacturers partially or fully charge battery cells and modules, which can lead to rising temperatures.

Unchecked thermal runaways pose a high risk; FLIR's thermal imaging technology can identify dangerous situations and 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. Our fixed-mount models can identify a higher number of potentially loose connections, significantly reducing end-of-line failures in battery systems. By integrating FLIR's automated thermal cameras into production lines, manufacturers gain several advantages:

• Both visual and thermal monitoring
• Up to 640 × 480 (307,200 pixels) resolution for detailed thermal images
• Custom-set alerts that notify you when a temperature threshold is crossed, ensuring no defects go unnoticed
• Compliance with industry-standard industrial protocols and video management systems including HMI, SCADA, and optional ONVIF S compatibility, ensuring easy integration