In Line Phased Array Inspection of Encapsulated Battery Structural Adhesives
Inline phased array testing maps structural adhesive wet-out and void formation through metal pack enclosures in real time at production line speeds.
Full Matrix Capture
Meaning
Data acquisition strategy records every possible transmit and receive combination from an array of ultrasonic elements. Each individual crystal in a probe fires once while all other crystals listen, creating a massive raw data set. In the context of battery weld inspection, full matrix capture provides the foundational information needed for advanced imaging.
Signal Collection
Time-domain signals from every path across the array are stored in high-speed buffers. Unlike traditional methods that focus on a single beam angle, full matrix capture gathers information from all directions simultaneously. This exhaustive capture ensures that no orientation of a defect is missed.
Post Processing
Algorithms analyze the stored waveforms to reconstruct a complete picture of the internal geometry. This step happens after the hardware has moved on, allowing for multiple types of analysis on the same data. Computers calculate the focal points for every pixel in the final image.
Detail Resolution
Sensitivity to small anomalies like porosity in tab welds improves when using this exhaustive data set. Because it captures the full sound field, full matrix capture enables the detection of cracks that are skewed or hidden behind other structures. This level of precision is necessary for verifying the electrical connections that must carry high currents in electric vehicles.
The ability to re-examine the data without rescanning the part provides a distinct benefit for forensic analysis of failed units.