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.
Total Focusing Method
Meaning
Imaging algorithm processes raw ultrasonic data to create a high-resolution map where every pixel is perfectly focused. It uses the information gathered during a full matrix capture cycle to calculate the constructive interference of waves at every point in a defined grid. Engineers apply the total focusing method to visualize the internal structure of battery welds and inter-cell connections.
Computational Reconstruction
Summing the amplitudes of signals from all transmitter-receiver pairs allows the software to generate a clear image at all depths. While traditional phased array systems focus at a specific range, the total focusing method provides clarity across the entire region of interest. The process requires significant processing power to handle the millions of calculations involved.
Flaw Detection
Improved spatial resolution allows for the identification of tiny cracks and inclusions that other methods might overlook. Small defects at the edges of a busbar weld become visible through the total focusing method. This capability is necessary for ensuring the long-term durability of electrical contacts in high-vibration environments.
System Performance
Accuracy in the final image depends on the correct input of material velocities and probe geometry. Because it produces a more intuitive visual output, the total focusing method reduces the specialized training required for technicians to interpret results. High-fidelity imaging leads to fewer false rejections of good parts.
This efficiency supports the high-throughput requirements of modern gigafactories. The resulting digital twin of the component acts as a permanent quality record for the life of the battery pack.