Battery Module X-Ray Geometry for Accurate Cell Gap Imaging
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Solution Overview
Problem
Current X-ray systems are inadequate for non-destructive material testing of vehicle battery modules, particularly in electric vehicles, as they fail to provide accurate imaging of gaps between battery cells due to oblique imaging geometries and insufficient resolution in the transverse direction.
Innovation Solution
An X-ray system with a beam angle of less than 10° and a large source-to-object distance, combined with multiple radiation sources and detectors, allows for precise imaging of gaps between battery cells by ensuring parallel beam alignment and reduced X-ray energy to penetrate only the gaps, not the cells themselves, using a combination of beam geometries and image processing techniques to compensate for superimposed structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a table top is provided to support writing materials and a keyboard, then the operational convenience is improved, but the device complexity increases
Solution Approach 1:
The patent combines the table top structure with the support legs into an integrated assembly. The table top is supported by multiple legs that are structurally merged with the main body, eliminating the need for separate mounting hardware and reducing overall device complexity while maintaining operational convenience.
Solution Approach 2:
The table top serves multiple functions: it supports writing materials for annotation, holds the keyboard for data input, and provides a stable working surface. This multi-functionality consolidates what would otherwise require separate devices, improving ease of operation without proportionally increasing complexity.
2Adaptability or versatility
If the C-arm is made movable to adjust the position of the X-ray generator and detector, then the adaptability is improved, but the stability of the object's composition deteriorates
Solution Approach 1:
The C-arm is designed with movable joints that allow dynamic adjustment of the X-ray generator and detector positions. The articulation points enable the C-arm to be positioned at different angles and heights to adapt to various examination requirements, while the controlled mobility maintains sufficient stability during imaging procedures.
Solution Approach 2:
The support legs act as intermediaries between the movable C-arm and the fixed base. They provide stable support during movement and maintain structural integrity when the C-arm is positioned, mediating between the need for adaptability and the requirement for stability.
3Ease of operation
If the keyboard and mouse are placed on the table top, then the ease of operation is improved, but the weight of the stationary object increases
Solution Approach 1:
The table top structure is designed to support the weight of the keyboard and mouse without requiring additional heavy reinforcement. The distributed load across the table surface and support legs allows the system to bear the weight of operational accessories while maintaining overall portability and ease of movement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and accurate detection of defects such as broken battery cell contacts and deformation, with minimal distortion, allowing for efficient non-destructive inspection of vehicle batteries.
Implementation Method 1
an X-ray generator (20)
Data Source
Figure 1a1~1b2
Figure 2
Figure 3a1~3b2
AI summary
The invention relates to an x-ray system for nondestructively testing the material of an object (106) to be radiographed, in particular a battery module (106b) of a vehicle or a battery module (106b) which is installed in a vehicle, having the following features: at least one radiation source (102); and at least one radiation detector (104); wherein the object (106) to be radiographed is arranged between the at least one radiation source (102) and the at least one radiation detector (104), the at least one radiation source (102) is spaced from the object (106) to be radiographed by a distance of at least double, at least triple, or at least quintuple the width (106b) of the scanning region such that a fan-shaped beam geometry is formed at least in the transverse direction, and the opening angle (100α) of the beam geometry is less than 10°.