Online viscosity sensors have many practical applications in the field of new energy vehicles, mainly including lithium battery production, motor lubrication status monitoring, etc. Here are some specific cases:
Monitoring of lithium battery production process: In lithium battery production, slurry viscosity is a key factor affecting coating quality. The online viscosity sensor can measure the viscosity of the slurry in real time and is connected to the automation control system. When the viscosity deviates from the set value, it can be automatically adjusted in a timely manner, such as adding solvent or adjusting temperature to change the viscosity, in order to improve product quality stability. Meanwhile, compared to traditional offline measurement, it can reduce detection time and intensity, improve production efficiency, and lower labor and time costs.
Monitoring of motor lubrication status: When the motor of a new energy vehicle is running, the viscosity of the lubricating oil is crucial for its lubrication effect and heat dissipation performance. The online viscosity sensor can monitor the viscosity of lubricating oil in real time. When the viscosity of lubricating oil changes due to local high temperature and high pressure oxidation or impurities, the sensor can provide timely feedback, allowing the staff to understand the quality status and remaining life of the lubricating oil, so as to replace the lubricating oil in a timely manner, ensure the normal operation of the motor, and extend the service life of the motor.
Transmission fluid monitoring: For new energy vehicles equipped with a transmission, the viscosity of the transmission fluid directly affects the smoothness of gear shifting and the service life of the transmission. The online viscosity sensor can monitor the viscosity of the transmission oil in real time. When the viscosity of the oil is abnormal due to factors such as wear particles and temperature changes, it will issue an alarm in a timely manner to remind the owner or maintenance personnel to inspect and maintain it, ensuring the normal operation of the transmission.
Monitoring of Resin Viscosity in Battery Boxes: The battery box mold developed by the German Aerospace Center uses 74 embedded sensors to monitor resin viscosity changes in real time. Combined with PID algorithm, it dynamically adjusts the temperature in each area, reducing the curing time difference between thick and thin walled areas to 15 seconds, avoiding local over curing or under curing. After applying this technology to the BMW iX3 battery box mold, the sealing life has been increased to 1200 cycles, which is three times longer than the traditional passive sealing solution. The Tesla 4680 battery box mold adopts this design, which reduces the porosity of the product from 3.2% to 0.8% and improves the electrical insulation performance by 2 orders of magnitude.
Stable power of flow battery: The viscosity data of the electrolyte to be entered into the pump body is obtained through a viscosity sensor. When the viscosity data of the electrolyte changes, the control module adjusts the pumping force of the pump body based on the viscosity data, changes the flow rate of the electrolyte, and thus stabilizes the power of the flow battery.