ELECTRIC VEHICLE PRODUCTION MICROSCOPE SOLUTIONS

OVERVIEW In an era of carbon neutrality, electric vehicles (EVs) can help optimize energy use in the field of transportation, reduce the consumption of petrochemicals, and minimize carbon emissions. Thus, EVs have entered a period of rapid development. With the continuous innovation needed for better battery and energy storage technology, the entire EV-industry suppy chain requires high-precision intelligent microscope solutions for efficient inspection, quality control (QC), failure analysis, and research and development (R&D). Leica Microsystems provides complete solutions for sample preparation...

BATTERY To further improve the safety and performance of electric vehicles, there are several challenges concerning the development and production of low-cost, reliable lithium batteries with high storage capacity. The risks of short circuits, thermal runaway, and fire caused by particle contamination, burrs, and critical defects on battery electrodes must be minimized. To overcome these challenges, strict quality control is required. Components of lithium-ion (Li-ion) batteries Quality control during battery production requires inspection of the cathode, positive electrode, and anode, negative...

Electrode inspection > Burr detection on electrodes High-performance microscopes are necessary to detect and help minimize burrs at electrode edges during battery production. Burrs can pierce the separator, cause short circuits, and possibly lead to thermal runaway, explosion, and fire. > Particle detection on electrodes Efficient particle detection on electrodes with cleanliness analysis using visual and chemical examination during battery production is important to minimize the presence of critical particles which can severely affect battery performance and lifetime. > Minimizing other defects...

BATTERY Cross section analysis of electrodes A deep understanding of battery electrodes requires cross-section analysis during QC, failure analysis, and R&D to evaluate the internal structure. However, cross-section preparation of electrodes can be challenging. Brittle materials may chip excessively and softer materials may smear, obscuring structures. The use of mechanical and ion-beam milling systems to prepare electrode cross sections can avoid such artifacts. High-resolution microscopy provides details of an electrode’s internal structure and layers. Cross section of a battery eletrode. Images...

Leica solutions To fulfill the needs of EV manufacturers concerning inspection, QC, failure analysis, and R&D of batteries, Leica Microsystems provides state-of-the-art solutions for sample preparation and microscopic observation and analysis. Leica solutions can help with the optimization of battery performance and production processes. For battery electrode inspection, there several Leica solutions available, including stereo, digital, and metallographic compound microscopes. For cross section analysis of electrodes, there are Leica sample preparation systems based on mechanical or ion-beam...

POWER ELECTRONICS CONTROLLER The user operation of an electric vehicle occurs via the power electronics controller. Additionally, special functions and programs, like “intelligent driving capabilities”, can be implemented in the controller to enhance vehicle operation and safety. PCBA large field of view splicing. Of course, the electronic and semiconductor components of the controller, i.e. PCBs, IC chips, and display panels, require inspection and QC during production, as well as failure analysis and R&D for constant improvement

PCB and component inspection Fast and reliable PCB inspection is important for power electronics controller performance. It can be achieved with a combination of optical microscopy and chemical analysis for visualizing defects and determining their chemical composition. Technical cleanliness of PCBs and components Contamination with conducting particles can cause short circuits and harm the performance of PCBs and their components. To minimize the presence of critical particulate contamination, an efficient cleanliness analysis for QC can be achieved with microscopy solutions. Cross section analysis...

POWER ELECTRONICS CONTROLLER Leica solutions Concerning QC, failure analysis, and R&D of EV power electronics controllers, Leica solutions for sample preparation and microscopic observation and analysis can help manufacturers optimize controller performance and production. There are a range of Leica stereo, digital, and compound microscopes for PCB and wafer inspection. Rapid and reliable technical cleanliness of PCBs and semiconductor components is addressed with Leica cleanliness analysis solutions. Fast and precise wafer and semiconductor inspection to ensure the quality and reliability of...

DM8000 M high throughput 8” inspection system. Contamination on the leads of an OLED display. RGB pixels of an OLED display.

MOTOR The motor is the heart of electric vehicles and consists of 3 main parts: stator, rotor and casing. To deliver the everincreasing desired vehicle performance, the motor should be efficient and reliable, so the load-bearing strength of the stator, rotor, and casing must be improved to overcome the challenges of achieving high torque, high drive efficiency, flexible torque control, etc. A more precise analysis of material properties and technical cleanliness, i.e., for the steel alloy used in the motor, copper wires in the stator, and aluminum alloy in the casing, can contribute to this goal....

Leica solutions Whether inspection, QC, failure analysis, or R&D of EV motors, Leica microscope solutions can help with the optimization of motor performance and production. Material and metallographic analysis is efficiently performed with Leica metallographic microscopes. For parts and components inspection, there are a range of Leica stereo and digital microscopes. Technical cleanliness is done rapidly and reliably using Leica cleanliness analysis solutions with both visual and chemical examination of particles. DM6 M microscope, K3 camera, and Cleanliness Expert analysis software. Structure...