EVs Explode

on Cargo Ship

to China

A fire erupted aboard the Morning Midas, a cargo ship enroute from China and transporting 3,048 vehicles, 751 of them EVs. While the exact cause of the fire is being investigated, the origin of the fire began from the deck containing the electric vehicles. Li-ion batteries have been associated with risks of thermal runaway. These fires, once started, become difficult to put out and emphasize the need for early fault detection.

X-ray remains one of the most effective methods in pre-fault detection of battery defects. To understand their effectiveness, it is important to understand the manufacturing errors that occur during production of batteries. There are a variety of faults that x-ray imaging can detect.

Electrode misalignment: 

When the anode and cathode layers are misplaced in pouch or prismatic cells, it can cause uneven current distribution which leads to localized heating, capacity loss or short circuits. X-ray can help by revealing the battery structure and ensuring they are properly aligned. 

Foreign Particles or Contaminants: 

During the manufacturing process, dust, metal shavings, or other debris can contaminate the battery. These contaminants can cause short circuiting which can potentially lead to thermal runaway and cause difficult to extinguish fires. Using x-ray, we can detect any high-density foreign objects within the cell layers of the battery, preventing potential disasters. 

Delamination or Layer Separation: 

Batteries consist of electrode layers and separators. When separation occurs, this reduces the contact area of the electrodes and reduces battery life. X-ray can be used to identify the gaps or air pockets between layers. 

Thickness Gauging: 

The density and electrode coating thickness must be uniform in order to ensure consistent performance. When there is irregularity in the thickness of electrodes and separators, this creates short circuits and can cause deformation due to gas build up or internal pressure. X-ray can be used in Computed tomography (CT) to map out a 3d volume of the battery and allow precise measurement of the uniformity and thickness of the layers within the battery. 

Early fault detection is vital during the manufacturing process to reduce the risk of field failure. This has the additional benefit of identifying faulty equipment or processes by investigating recurring defects. The process of using x-ray can allow inspection while leaving the batteries intact and usable after inspection. 

VJ X-ray manufactures a variety of x-ray sources that assist with multiple steps of inspection in the production process. These include thickness monitoring of separator film and cathode coating process, wrinkle inspection after winding, and package inspection before shipments. Our growing catalog of x-ray sources include everything needed to integrate into inspection systems. 

Our speciality includes a growing catalog of products to meet the increasing need for inspection requirements. We stand ready to work with manufacturers around the world to deliver quality and performance with our team of experts.