Reliability of Non-Destructive Testing in the rise of electric mobility

Inspenet, November 5, 2023. Non-destructive testing (NDT) plays a fundamental role in guaranteeing operational reliability in the field of electric mobility. The choice of these methods for testing electric vehicles will depend on the specific components you wish to inspect and the materials involved in the components.

José López.

Published: November 5, 2023

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Author: Inspector/Analyst. Jose G. López, M. November 5, 2023.

Introduction

Non-destructive testing (NDT) plays a fundamental role in guaranteeing operational reliability in the field of electric mobility. The choice of these methods for testing electric vehicles will depend on the specific components you wish to inspect and the materials involved in the components.

In the automotive industry, Non-Destructive Testing methods play a considerable role in vehicle quality control. These technologies are applied in various areas such as research and development, manufacturing and automobile maintenance.

This article introduces a variety of technologies, such as radiography, penetration testing, eddy current detection, ultrasonic inspection, magnetic particle inspection, and laser holographic inspection.

Non-Destructive Testing for the evaluation of electric vehicles

Visual inspection: It is a fundamental technique that allows inspectors to visually examine vehicle components for obvious defects, damage or wear. It is the starting point and can detect surface problems, such as cracks, corrosion or damage to the casing.

Ultrasonic inspection: Uses ultrasonic waves to evaluate the integrity of metal components, such as axles, chassis, and aluminum frames. It can detect internal defects, such as cracks, inclusions and discontinuities in metallic materials.

X-ray: Used to inspect electrical and electronic components, such as batteries and circuit boards. It allows you to detect internal defects, such as faulty welds or damaged internal components.

Infrared thermography: Uses thermal cameras to identify temperature variations in electrical and electronic components. This may reveal overheating, connection problems, or defects in electrical components.

Electrical and electromagnetic tests: These tests evaluate electrical conductivity, continuity of circuits and the quality of electrical connections. They are used to identify problems in control systems, batteries and electric motors.

Applications of NDT in the field of electric mobility

Below are some applications in this context:

Connector testing: Used to evaluate the integrity of connectors used in electric vehicles. This involves the use of techniques such as x-ray and ultrasound testing to detect defects such as manufacturing flaws, wear, corrosion or improper handling in the connectors.

Motor Test: Used to evaluate electric motors. This includes magnetic particle inspection to detect cracks or other defects in motor components, as well as eddy current testing to identify the presence of corrosion or other defects in motors.

Charging Station Test: Allows you to evaluate charging stations for electric vehicles. This may include ultrasonic testing to detect defects in charging cables and x-ray testing to identify possible defects in charging connectors.

Reliability of ENDs and their application in electric mobility

The rise of electric mobility has led to a growing reliance on Non-Destructive Testing (NDT) when it comes to the operational reliability of electric vehicles and their associated infrastructure. These NDTs play an essential role in the production, maintenance and safety of critical components of electric vehicles, ensuring their optimal performance and the prevention of catastrophic failures.

Electric vehicles, powered by high-tech batteries and electrical systems, rely heavily on high-quality components and materials for their safe and efficient operation. Inspection and evaluation of these components have become essential to ensure the reliability of electric vehicles and to meet safety and quality standards required by industry and regulators.

NDTs are used at all stages of the life cycle of electric vehicles, from the inspection of raw materials and components in the manufacturing phase, through quality monitoring during production, to maintenance and periodic inspection of vehicles in operation. These advanced techniques allow us to identify and evaluate possible defects, failures or wear in critical components such as batteries, electric motors, charging systems and other essential elements.

Electric mobility demands rigorous quality control and exceptional operational reliability, as electric vehicles are intended to be a sustainable transportation solution with low environmental impact. Safety and optimal performance are critical to earning consumer trust and meeting expectations for durability and efficiency.

In this context, NDT are applied to detect and prevent problems such as corrosion in metal structures, defects in welds, failures in batteries and electronic components, as well as wear in transmission and braking systems. Additionally, inspection of charging infrastructure, including charging points and cables, is equally essential to ensure safe and efficient charging of electric vehicles.

The rise of electric mobility has driven innovation in NDT techniques and technologies, leading to the creation of more advanced and precise inspection equipment and systems. Early detection of possible problems allows preventive measures to be taken, reduce maintenance costs and avoid possible incidents, which contributes to the operational reliability of electric vehicles and the safety of users.

In summary, the growth of electric cars has elevated the importance of Non-Destructive Testing in the operational reliability of electric vehicles and their associated infrastructure. These techniques play a crucial role in the production, maintenance and safety of the key components of electric vehicles, ensuring their optimal functioning and meeting the quality and safety standards required in this new era of sustainable mobility.

Conclusions

At the same time with the rapid development of electronic technology and computer technology, NDT technology in automotive area is also constantly changing towards acceleration, digitalization, efficiency, and more and more these technologies show the characteristics of high sensitivity, high stability and high efficiency.

At present, non-destructive testing technology is gradually being combined with artificial intelligence, adaptive technology, computer technology and CAD computer-aided design, etc.

Gradually developing three-dimensional ultrasonic scanning inspection imaging technology, to present the internal structure information of the inspected object more comprehensively. At the same time, integrating the entire inspection process at the stage of design, production and application of automobile components, to achieve the quality control level of automobile manufacturing, providing reliable electric mobility.