INFICON, a global manufacturer of leak-testing devices and instruments, recently demonstrated its leak-tightness testing imperative at The Assembly Show in Rosemont, Illinois.
ELT3000 PLUS electrolyte leak detector sets new standards for inline testing in automated high-speed battery production lines, ensuring non-destructive battery leak testing of liquid electrolyte-filled battery cells of all formats.
For 20 years, manufacturers have been trying to automate leak detection on hand braze copper tubing. INFICON has recently partnered in developing a vision system capable of picking up on discrepancies of hand-brazed copper tubing from part to part. It’s the first and only company with the capability of this new, innovative Vision System that will allow customers to automatically detect the variations of hand-brazed components with a robotic arm.
EV battery manufacturing solutions
INFICON’s array of leak-detection solutions is designed to cover every aspect of leak testing for EV battery cells and battery packs, and for FCEV battery cells, battery stacks, and hydrogen systems — with precise, repeatable measurements, and the highest quality using INFICON’s proprietary software for measurement and reporting.
Traction battery cells and battery packs for EVs and FCEVs require leak testing to prevent liquid water or water vapor and humidity ingress, loss of medium or crossover of medium to ensure optimal battery performance, as well as battery and vehicle safety.
INFICON’s new ELT3000 PLUS leak detector, which is specifically designed for leak testing final-filled lithium-ion and sodium-ion battery cells by direct detection of electrolyte solvent leaking into a test chamber.
For end-of-line testing, just one ELT3000 PLUS operates several test chambers, to provide high-speed, high-throughput, high-quality leak detection in seconds for all cell formats — prismatic, cylindrical, pouch and coin — in-line at the pace of the production line. The ELT3000 PLUS can also be operated in manual mode for engineering trials or pilot production lines.
Leak-detection for EV battery packs
With more than 300 places for potential leaks in EV battery packs, INFICON’s tracer gas sniffer leak-testing solutions can quickly pinpoint a leak at the micron level, saving hours in repair time and costly recalls, while ensuring the highest quality.
They also can be integrated as part of the battery pack manufacturing process or for end-of-line testing. Manufacturers can select a system based on the need for measurement level, reproducibility of results and the speed of leak-tightness testing.
- On display, INFICON XL3000flex: Also using the high-flow technology with 3000 sccm, in conjunction with a robust mass spectrometer, the system guarantees the highest level of measurement sensitivity over large areas. Regardless of using helium or forming gas (5% hydrogen in nitrogen), even the smallest amounts of tracer gas can be reliably detected.
Leak-detection for FCEV fuel cells and drives
The challenge for leak testing in hydrogen fuel cells is to detect hydrogen leaking out of the cell. Diminished levels of hydrogen create the risk of vehicles losing power, which is a safety risk for vehicles in motion. Also, uncontrolled emissions of hydrogen can negatively impact safety and reliability in the FCEV system.
- FCEV fuel cell stacks/hydrogen fuel tanks: INFICON’s XL3000flex offer dynamic sniffer leak detection for end-of-line leak detection of fully assembled hydrogen fuel tanks and complete fuel cell stacks. A continuously moving sniffer detects tracer gas escaping from the test parts in seconds.
INFICON researchers and engineers are active participants in SAE Standards Committees to define leak detection specifications for cooling circuits for lithium-ion battery packs used in EVs; and a committee examining preventing water ingress for lithium-ion battery cells.
Filed Under: Battery Pack, Technology News