Monitoring of Soundness of Power Supply Bus Bar (In-vehicle Lithium-ion Battery Applications)

The DTSX is a unique and innovative temperature monitoring system that uses fiber optic cable as a temperature sensor.

Current Issues

Lithium-ion Battery Production Stoppages Caused by Abnormal Overheating of Bus Bar

Bus bars capable of supplying large current are used as power supply bus lines, for example, for charging large numbers of batteries at in-vehicle lithium-ion battery production lines.
Although monitoring of the soundness of power supply lines is important, at present, only manual periodic maintenance is performed, and power supply lines cannot be thoroughly and constantly monitored.

Lithium-ion Battery Production Stoppages Caused by Abnormal Overheating of Bus Bar


Bus ducts
Bus ducts

Power stoppages occur suddenly when an abnormality occurs on the bus bar.
Abnormalities are generally damage or burning caused by overheating of the joints of the bus bar.
Bus bars are joined together by tightening bolts. However, when these joints are loosened by earthquakes or other factors, electrical resistance increases which causes temperature to rise. Overheating, in turn, causes electrical resistance to increase even further which leads to breakage and burning of joints.

When power is interrupted, this directly causes battery production line stoppages and considerably impacts automobile production processes.
All kinds of risks are probable - late deliveries, trust issues and drop in product competitiveness.


Solutions and Benefits

Fiber Optic Cable Visualizes The Soundness of Bus Bars

As bus bars are located in roof space, under floors and other difficult-to-access places after being fitted into bus ducts, it is difficult for personnel to inspect bus bars thoroughly and there is the risk of overlooking abnormalities. Also, it is difficult to discover abnormalities at an early stage.
Moreover, in the case of electrical type temperature sensors, sensors are subjected to the influence of strong electrical fields caused by the large current of the bus bar, and this makes it difficult to measure temperature normally.

Fiber Optic Cable Visualizes The Soundness of Bus Bars

With a fiber optic heat detector DTSX1, the sensor is never subjected to the influence of strong electrical fields from the bus bar as temperature is measured by light.
Abnormal overheating of the bus bar is also conducted to the bus duct.

For this reason, the temperature distribution can be constantly monitored along the entire length of the bus duct, and the soundness of the bus bar can be ensured without overlooking abnormal overheating simply by laying fiber optic cable along the bus duct. All routes along the bus duct can be covered by a single DTSX1. For this reason, a system for monitoring the soundness of power lines at all times, which has been impossible to monitor by personnel and existing temperature sensors, can now be economically installed.
The DTSX1 is also in use likewise in bus ducts for industry sectors other than lithium-ion batteries such as data centers.


Features of "Optical Fiber Sensing" in DTSX System

The Fiber Optic Cable Is The Temperature Sensor  

Temperature distribution monitored every 1 m

Temperature distribution monitored every 1 m

  • Monitoring distance : to 50 km
  • Monitoring temperature : -200 to 300 °C
  • Shortest monitoring cycle : Approx. 5 seconds
  • Temperature resolution : 0.03 °C

*: each specification dependent on conditions/p>

Main Features

  • 24 hours, 365 days monitoring even in wide areas and ordinarily non-manned areas
  • Power supply not required, explosion-proof, not affected by electromagnetic noise
  • Flexible installation
  • High compatibility with DCS and other host systems (Modbus/TCP)


Other In-vehicle Lithium-ion Battery Applications

Smart Monitoring of Manufacturing Process Shelves and Storage Shelves

Thermal runaway of lithium-ion batteries mounted on individual shelves is discovered at an early stage. This enables a quick initial response when an abnormality occurs to limit damage to a minimum.
(For details, refer to "Smart Monitoring of Manufacturing Process Shelves and Storage Shelves -In-vehicle Lithium-ion Battery Applications- ".)

Smart Monitoring of Manufacturing Process Shelves and Storage Shelves


Prevention of Fires in Exhaust Air Ducts in Battery Assembly Process

Fires or dust explosions in exhaust air ducts for preventing the contamination of aluminum dust in the assembly process of lithium battery batteries are monitored. Abnormalities are not overlooked as ducts extending over long distances in blind areas such as roof space are comprehensively monitored.
(For details, refer to "Prevention of Fires in Exhaust Air Ducts in Battery Assembly Process -In-Vehicle Lithium-ion Battery Applications-".)

Prevention of Fires in Exhaust Air Ducts in Battery Assembly Process


Checking of Separator/Electrode Coating Drying Furnace Temperature Distribution

The temperature distribution inside the drying furnace of the coating drying process for the separators/electrodes that make up a lithium-ion battery is visualized. Optimizing the temperature profile improves productivity.
(For details, refer to "Monitoring of Separator/Electrode Drying Furnace Temperature Distribution -In-Vehicle Lithium-ion Battery Applications-".)

Checking of Separator/Electrode Coating Drying Furnace Temperature Distribution



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