More efficient automotive manufacturing inspection with high-energy computed tomography
06/09/2024
With the rapid technological advancements in the automotive industry, demand for innovative inspection solutions has become paramount. One such breakthrough is high-energy computed tomography (CT), revolutionising the inspection process by providing unparalleled detail and insight into complex assemblies. North Star Imaging explains…
Low-energy X-ray computed tomography (CT) imaging (sub-600 kV) has been a common choice for industrial parts. Typically capable of resolutions in the single-digit micron range, this granular detail easily shows fine features such as the individual layers in the latest batteries, as shown in Figure 1. The shift towards electric vehicles (EVs), with their intricate battery modules and large electric motors, underscores the need for more sophisticated inspection capabilities to meet the increased industry standards. These large and complex assemblies require a much higher energy source to penetrate their dense composition.
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| Figure 1. 2D slices of a hybrid battery module showing components with very different densities sectioned from one CT scan |
Utilising a state-of-the-art 9 MeV linear accelerator (LINAC), companies are able to achieve unprecedented levels of accuracy and clarity in their scans, resulting in higher image quality with reduced noise, reduced scatter and reduced beam-hardening artefacts that negatively impact the image fidelity of a part.
Another key advantage of high-energy CT is its ability to inspect fully assembled components, such as large electric motors, battery modules and transmissions, without the need for disassembly. This approach not only saves time and resources but also minimises the risk of damage to delicate components. In a single scan, materials with vastly different densities (for example aluminium, steel, copper, plastics and epoxy) can be visualised with exceptional clarity, providing a comprehensive view of the entire assembly. Additionally, battery modules up to 36" wide are able to be scanned at certain facilities.
Figure 2 clearly shows the pure latitude of materials that can be accurately represented with high energy. The plastic battery case can be seen here, along with steel and other higher density materials. Notice there are no streaking artefacts from the high density into the low density.
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| Figure 2. High-energy CT scan showing both plastic and steel clearly in the same image |
The advantage of efficiency for not having to disassemble modules is apparent in this example. The high-energy CT scan, when coupled with advanced software and experienced CT subject matter experts, allows for clarity and accuracy without disassembly. Figure 3 shows the range of materials in the whole module. Everything can be identified in this one image, from lead or tin solder,
printed circuit board (PCB) substrate, copper buses, plastic battery cases, steel screws, the steel outer module case, lithium-ion battery cells, copper wires and other materials.
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| Figure 3. Multi-material densities are available in one scan for efficient inspection and dimensional analysis |
As technology continues to evolve, so too will the capabilities of high-energy CT. With ongoing advancements in imaging technology and data analysis techniques, the future of manufacturing inspection looks brighter than ever. By embracing innovation and investing in state-of-the-art solutions such as high-energy CT, manufacturers can stay ahead of the curve and unlock new possibilities in quality assurance and product development.
In conclusion, high-energy computed tomography represents a quantum leap forward in the field of manufacturing inspection. With its ability to penetrate dense materials, image materials of various densities without disassembly of modules, detect hidden defects and provide comprehensive visibility across the entire production chain, high-energy CT is poised to revolutionise the way
products are designed, produced and inspected. As industries continue to evolve and embrace new technologies, the role of high-energy CT will only become more indispensable, driving innovation, efficiency and quality in manufacturing processes worldwide.
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