Coral Springs, FL and San Diego, CA (PRWEB) March 9, 2009
Development of a non-destructive test (NDT) system for quality control of welds in ultracapacitor electrode structures allows the manufacturer to avoid placing defective electrodes into their cases and makes it possible for operators to detect defective electrode welds prior to sending ultracapacitors to the next assembly step.
This system can be highly effective in improving product quality, reliability and product cost. Since the electrode "jellyroll" structures of ultracapacitors and conventional batteries are similar, this NDT system also can be used in the manufacture of batteries.
Welding quality is monitored without physical contact by use of new NDT devices. The air clearance between the electromagnetic sensor and the surface of the bottom collector slot is 0.25 mm. The non-contact mode of testing can also successfully be applied in quality evaluation of welding in automated ultracapacitor assembly line manufacturing.
The design of the new system allows determination of weld quality for each slot of the collector. For example, for a collector with four slots, the device uses eight transducers (four for cathode and four for anode collectors). Movable electronics modules are employed to control sensor parameters and for preliminary amplification and signal processing. The electromagnetic NDT system, designated as the EC - TLW, is fully integrated into a compact package. It is user friendly and can be adapted to a number of product quality assessment tasks.
Robert Crawford, Maxwell's director of operations, commented, "Enerize has developed a non-destructive eddy current measurement system for Maxwell that can detect quality problems with our laser welds. This is a proof of concept system that will be used to optimize our laser welding process and ultimately improve our system equivalent series resistance (ESR) as we optimize weld quality. Eventually we would invest in an automated system that will test 100% of our welds."
Dr. Elena Shembel, President/CEO and co-founder of Enerize Corporation, commented, "We believe that the new non-destructive method is extremely effective in detecting hidden faults in ultracapacitors. It is a major further breakthrough of Enerize's activity in the field of non-destructive technology for the ultracapacitor and battery industries to test initial materials, semis and final product. We are looking toward to further collaboration with Maxwell in development of non-destructive testing devices for the ultracapacitor industry."
Enerize Corporation provides proprietary technology and technical know-how in non-destructive testing for various applications with an intellectual property portfolio that includes several issued and pending patents in areas critical to the advancement of the ultracapacitor, battery, solar energy and chemical industries.
About Enerize Corporation:
Enerize Corp. is an emerging technology company founded by renewable energy industry veterans. The Company develops and markets proprietary technology and technical know-how in non-destructive testing equipment for real time applications in the manufacture of the renewable energy devices. Enerize Corp. also develops advanced designs and high performance, low cost materials and technologies used in solar cells, lithium-ion batteries, fuel cells and supercapacitors. The Enerize Corp. management team is comprised of executives and board members with decades of expertise in the renewable energy technology and business development. Enerize Corp. intellectual property includes more than twenty US and international patents and patent applications in areas critical to the advancement of the renewable energy industry. For more information, visit http://www.enerize.com/ or e-mail info (at) enerize (dot) com.
Email: eshembel (at) enerize (dot) com
About Maxwell Technologies Inc.
Maxwell is a leading developer and manufacturer of innovative, cost-effective energy storage and power delivery solutions. Our BOOSTCAP® ultracapacitor cells and multi-cell modules provide safe and reliable power solutions for applications in consumer and industrial electronics, transportation and telecommunications. Our CONDIS® high-voltage grading and coupling capacitors help to ensure the safety and reliability of electric utility infrastructure and other applications involving transport, distribution and measurement of high-voltage electrical energy. Our radiation-mitigated microelectronic products include power modules, memory modules and single board computers that incorporate powerful commercial silicon for superior performance and high reliability in aerospace applications. For more information, please visit http://www.maxwell.com.