Prevention of Fires in Exhaust Air Ducts in Battery Assembly Process (In-vehicle Lithium-ion Battery Applications)

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

Current Issues

Risk of Fires / Dust Explosions in Assembly Process and Impact on Business

In the lithium-ion battery assembly process, air is taken in via exhaust air ducts to eliminate the influx of contaminants. However, there is the risk of dust explosions as fine aluminum dust is taken in during the process. Almost all parts of exhaust air ducts extending over long distances installed in buildings are in blind spots such as roof space, and fire smoke due to dust explosions is discharged outside of the building. Consequently, fire tends to be discovered late.

Risk of Combustion of Lithium-ion Batteries in Aging Process Shelves and Impact on Business

Emergency stoppages in the assembly process not only cause production loss but also the adverse affect of late deliveries, trust issues and drop in competitiveness has a major social and economic impact on society and the economy.


Solutions and Benefits

Fiber Optic Cable Ensures the Comprehensive and Economic Monitoring of Exhaust Air Ducts in Assembly Process

In addition to the increased need for patrols and maintenance such as the cleaning of exhaust air duct, the roof space where the duct is installed is environmentally harsh - dark or cold (or hot).
Moreover, as installation sites are located in high (i.e. Dangerous) places, an additional load is placed on work. Monitoring independent of manpower is important to prevent fire or dust explosion.

Fiber Optic Cable Ensures the Comprehensive and Economic Monitoring of Exhaust Air Ducts in Assembly Process

However, conventional sensing methods considered as means of monitoring these are subject to the following limitations.

  • Thermo camera: Many units (i.e. large investment) are required to cover exhaust air ducts in roof space that has lots of blind areas.
  • Point sensor: Sensors must be sited at many points along the exhaust air ducts that extend over long distances.
    The number of man-hours required for their installation, wiring, treatment of cable ends, and other work is considerable. And, the risk of failure increases.

With the fiber optic heat detector DTSX1, fiber optic cable is laid in even ducts that extend long distances. This is more economical than conventional sensing methods, and all exhaust air ducts can be comprehensively monitored.

It can be flexibly configured and set to suit on-site environments as a means of detecting abnormal temperature in a way different from that of point sensors as it supports a difference with external thermometer alarm in addition to simple upper limit and rate-of-change alarms. This leads to discovery at an early stage and quick initial response which limits damage to a minimum.
DTSX1 conforms to EN54-22 the EU fire detection and fire alarm system standard, and is currently used as a fire detection sensor.
It is also in use likewise in ducts for industry sectors other than lithium-ion batteries.


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

Main Features

  • 24 hours a day, 365 days a year 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

Monitoring of Soundness of Power Supply Bus Bar

The soundness of the joints of the power supply bus bar installed in lithium-ion battery is monitored. Abnormalities are not overlooked as fiber optic cable is built into the bus duct and bus bars extending over long distances in blind areas such as roof space are comprehensively monitored.
(For details, refer to "Monitoring of Soundness of Power Supply Bus Bar -In-vehicle Lithium-ion Battery Applications-".)

Monitoring of Soundness of Power Supply Bus Bar


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


Monitoring 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-".)

Monitoring of Separator / Electrode Coating Drying Furnace Temperature Distribution



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