X-Ray Inspection Geometry for Battery Cell Gap Detection
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Solution Overview
Problem
Existing X-ray systems are inadequate for non-destructive material testing of battery modules in vehicles, particularly for assessing mechanical integrity after accidents or in second-hand vehicles with unclear history, due to limitations in resolution and ability to distinguish between battery cells and gaps.
Innovation Solution
An X-ray system with a fan-shaped radiation geometry, limited opening angle, and increased source-detector distance is used to scan battery modules, allowing for high-resolution imaging of gaps between cells while minimizing absorption by cells, using multiple radiation sources and detectors for comprehensive scanning and image processing to compensate for overlapping structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional X-ray system with small source-detector distance is used, then the radiation intensity is sufficient for imaging, but the resolution is inadequate to distinguish gaps between battery cells
Solution Approach 1:
The patent transitions from a conventional parallel beam geometry to a fan-shaped radiation geometry by positioning the radiation source at a distance of at least five times the width of the scanning area. This dimensional change in the radiation source arrangement creates a fan-shaped beam that naturally focuses on the object plane, achieving high resolution without requiring extremely high radiation intensity. The fan-shaped geometry allows the radiation to converge on the battery module, improving image quality while maintaining acceptable radiation levels.
2Use of energy by moving object
If the radiation source is placed close to the object, then the radiation intensity is high, but the opening angle becomes too large causing poor distinction between cells and gaps
Solution Approach 1:
The patent changes the critical parameter of source-detector distance from conventional small values to at least five times the width of the scanning area. This parameter change fundamentally alters the radiation geometry, creating a fan-shaped beam with a controlled opening angle. The large distance ensures that the opening angle remains small enough to distinguish between battery cells and gaps, while the fan-shaped geometry maintains sufficient radiation intensity through natural convergence on the object plane.
3Productivity
If a large opening angle is used, then the scanning area is covered quickly, but the resolution and ability to detect defects is reduced
Solution Approach 1:
The patent employs dynamic scanning where the object (vehicle with battery module) moves through the fan-shaped radiation field. This dynamic approach allows the use of a controlled opening angle that provides both adequate scanning coverage and high resolution. The motion of the object through the radiation field enables comprehensive scanning while maintaining the small opening angle necessary for defect detection, resolving the contradiction between scanning speed and detection precision.
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 efficient detection of defects and deformations in battery modules by clearly imaging gaps between cells, facilitating fast and accurate assessment of battery integrity without damaging the cells, suitable for various vehicle types and designs.
Implementation Method 1
an X-ray system for non-destructive material testing of an object to be irradiated
Implementation Method 2
minimizing absorption by cells
Data Source
AI summary
X-ray system for non-destructive material inspection of an object to be irradiated, in particular of a battery module of a vehicle, or a battery module incorporated in a vehicle, comprising at least one radiation source; at least one radiation detector; wherein the object to be irradiated is arranged between the at least one radiation source and the at least one radiation detector, wherein the at least one radiation source is arranged spaced apart from the object to be irradiated with at least two times, or at least three times, or at least five times the width of the scanning area (such that a fan-shaped radiation geometry is formed at least in transverse direction), wherein the opening angle of the radiation geometry is less than 10°.