Thermography in the detection of thermal leaks in electric and internal combustion vehicle batteries
Electromobility is advancing rapidly, and with it comes a growing need to ensure safety and efficiency in electric vehicles. One of the biggest challenges in this sector is thermal runaways in lithium-ion batteries, which can cause everything from performance failures to critical risks such as fires or explosions.
Infrared thermography is now an indispensable tool for anticipating these risks. With FLIR thermal imaging cameras, it is possible to detect temperature anomalies in battery cells and modules in real time, identifying hot spots invisible to the human eye. Even a small temperature variation can be the first sign of a manufacturing defect, deterioration in insulation, or the start of an internal leak.
Why use thermography on electric vehicle batteries?
FLIR thermal imaging cameras allow for rapid, contactless identification of abnormal temperature variations in battery cells and modules. Thanks to its high thermal sensitivity, thermography facilitates:
- Early detection of hot spots before they lead to thermal runaways.
- Prevention of failures during assembly and quality testing.
- Real-time monitoring during vehicle operation and charging.
- Reduction of safety risks, protecting both users and facilities.
- Optimization of battery life through preventive and predictive control.
FLIR thermal imaging cameras applied to automotive battery inspection. They are already key tools in the electromobility industry
FLIR, a global leader in infrared vision technology, offers specific solutions for the automotive and e-mobility sectors. Models such as the FLIR X8581 and FLIR A8581 stand out for their precision and high-speed analysis capabilities, ideal for laboratory testing, design validation, and quality control.
Furthermore, the A700 and A70 cameras, when integrated into automated monitoring solutions such as the bcbMonitor5, allow thermography to be integrated into continuous inspection systems within battery production plants.
Benefits for the Automotive Industry
The implementation of thermography with FLIR cameras offers direct benefits to manufacturers and suppliers:
- Greater safety in the production and operation of electric vehicles.
- Savings in warranty costs by detecting defects before delivery.
- Compliance with international safety regulations.
- Strengthening customer confidence in electrical technology.
The integration of infrared sensors and continuous monitoring systems such as bcbTestbench reinforces prevention, providing traceability and immediate alarms that can activate safety protocols before a problem turns into a fire. Not only does it increase safety in the manufacturing and use of electric vehicle batteries, but it also protects investments and strengths.
In addition to affecting process quality, an overheated battery poses a risk of thermal runaway or fire.