Electric vehicles are rapidly transforming the automotive landscape. EVs contribute to cleaner air by producing low or no emissions during operation.

Unlike traditional internal combustion engine (ICE) vehicles that emit pollutants, EVs help combat air pollution and mitigate climate change.

Essa mudança de veículos de gelo para EVs apresenta desafios únicos devido às diferenças fundamentais nesses dois sistemas de energia.

Therefore, it is essential to assure high-quality of battery systems as manufacturers and suppliers accelerate their engineering research, development, and production in EVs.

An electric vehicle battery serves as the rechargeable energy storage system that powers the electric motors in battery electric vehicles.

These batteries are typically lithium-ion and are designed for a high power-to-weight ratio and energy density, contributing to the overall performance of the vehicle.

EV battery packs consist of several critical components, including battery modules, thermal management systems, battery management systems (BMS), electrical connectors, and structural elements.

Entre eles, os componentes estruturais, incluindo a estrutura da bateria, a tampa superior e a bandeja da bateria - desempenham um papel fundamental.

Eles servem como esqueleto da bateria, garantindo sua segurança e integridade estrutural.

As the demand for EVs continues to surge, meticulous Inspeção e controle de qualidade Desses componentes da bateria, se tornam essenciais para garantir o desempenho e a segurança ideais na estrada.

A aplicação de scanners 3D na inspeção de baterias de EV

Quadro da bateria

The battery frame is a critical structural component that houses battery modules and their supporting systems. Proper fit and alignment are important to prevent assembly issues, electrical disruptions, and heat transfer problems.

It comprises several structural components, including side rails and cross members. Key measurement points include installation hole positions, welding locations, slots to obtain relevant dimensions and positional accuracy.

Battery frames are large and often produced in harsh shop floor environments. Traditional methods are time-consuming and may not cover the entire tray in a single position.

Portable 3D laser scanners that are not sensitive to environment conditions such as vibrations and temperature variations are necessary.

KScan - Scanner 3D portátil mágico can conduct on-site 3D scanning and obtain precise measurement results. It capture data faster than traditional methods with a measurement rate of up to 4.15 million measurements/s.

O sistema de fotogrametria integrado a este dispositivo apresenta uma área de disparo que medindo 3760 mm por 3150 mm.

This function effectively mitigates the cumulative errors associated with large-scale measurements, thereby ensuring high volumetric accuracy.

Tampa da bateria e bandeja

Due to their substantial size and stringent quality requirements, the battery cover and tray play a crucial role in ensuring the sealing integrity and assembly quality of the battery.

To mitigate safety risks, it is imperative to conduct a comprehensive inspection on both the profile, flatness, parallelism, and dimensions.

Notably, the width of the battery tray and cover typically exceeds 1.6 meters, which poses challenges for accurate measurement using traditional measurement methods.

Scantech’s Sistema de medição 3D óptica TrackScan - SharP possui grandes volumes de medição de até 49 m3, capazes de medir peças grandes e grandes.

This means the 3D measurement system can capture a large amount of data in one position to reduce inspection time. There is no need to move trackers frequently. Besides, it can quickly capture details of parts and obtain high-precision 3D data.

To ensure assembly quality, manufacturers can also conduct deformation inspection and analysis on trays and covers before and after assembly.

Orifícios da bandeja da bateria

When inspecting the holes of the battery tray, key measurements primarily focus on positions and diameters of holes that come in various sizes and types.

Sistema de medição 3D óptica TrackScan - Sharp pode ser usado para obter uma inspeção precisa e eficiente de orifícios.

Este sistema apresenta sombra - Inspeção de borda menos leve alimentada pela medição de valor de cinza alta - precisão.

It allows users to meticulously inspect closed features, particularly threaded holes. The system ensures accurate and repeatable measurement results, including position and diameter information.

Além disso, captura dados 3D cruciais relacionados a posições de orifício, diâmetros e espaçamento.

Para avaliar a precisão posicional dos orifícios de instalação rosqueados, pode ser usada colunas auxiliares com rosqueamento de alta precisão especializados.

These columns can adapt to various threaded hole sizes (such as M5, M8, and M10), enabling 3D scanners to capture precise data for threaded holes better.

If the accuracy requirement is not too high, we can also use a 3D scanner to scan the hole position and the outer surface of the cylinder to obtain the positional accuracy of the threaded holes.

Sistema de Gerenciamento de Bateria (BMS)

O sistema de gerenciamento e controle de células da bateria é o componente principal da bateria e requer instalação precisa.

Podemos usar uma sonda para detectá -la e analisá -la durante o processo de instalação para garantir sua precisão após a instalação.

Fluxo de trabalho para varredura 3D

First, attach markers to the part. When using optical 3D measurement system, markers are not necessary.

Next, conduct non-contact 3D laser scanning of the entire tested part.

Obtain and process the 3D data of the part in 3D software.

Finally, compare this data with the standard CAD model to identify dimensional deviations at each position.

This process allows for quicker acquisition of precise data and enhances inspection efficiency.

Vantagens da varredura a laser 3D

Alta precisão

3D scanners provide meticulous insights into the intricate structures of electric vehicle (EV) batteries, guaranteeing safety, reliability, and peak performance over their entire lifespan.

With an impressive accuracy level of up to 0.020 mm, these measurement techniques play a crucial role in maintaining the high quality of battery assessments.

Eficiente

Due to the easy operations and rapid measurement rate of 3D scanners, measuring electric vehicle (EV) batteries using this technology is highly efficient.

The ability to capture detailed 3D data quickly allows for precise assessments of battery components, including their shape, dimensions, and any potential defects.

Whether in research and development, manufacturing, or quality control, 3D scanning streamlines the battery measurement process, leading to improved accuracy and productivity.

Varredura 3D completa

3D scanning is an optimal choice for comprehensive measurement to create a digital twin of components, which ensures that engineers capture every intricate detail without overlooking anything.

By employing this method, they gain a complete and accurate representation of the part, facilitating precise analysis and quality control.

Dados abrangentes

These comprehensive 3D data can be stored for in-depth analysis. They provide a complete view of the part’s condition, enabling engineers to verify its quality thoroughly.

Além disso, os usuários podem identificar facilmente as especificações geométricas de dimensionamento e tolerância (GD&T) da peça.