Early Heat Anomaly Detection: The Key to Lithium-Ion Battery Safety

Lithium-ion batteries are widely used for their energy efficiency, long lifecycle, and high power density. However, the increasing prevalence of lithium-ion battery fires presents a significant safety risk, especially during the hot summer months. Fires caused by these batteries have multiplied fivefold since 2016, with incidents leading to fatalities and property damage. In Vancouver, Canada, seven people tragically died in 2022 due to fires related to lithium-ion batteries. This highlights the critical importance of detecting heat anomalies early and taking proactive fire prevention measures.

Differences Between Lithium and Lithium-ion Batteries

Lithium Batteries (Primary Batteries): Non-rechargeable batteries that are ideal for applications requiring high energy density in a compact form. These batteries contain lithium metal, which is highly reactive and combustible.
Lithium-ion Batteries (Secondary Batteries): Rechargeable batteries with high energy density but lower than lithium primary batteries. These are used in everything from electric vehicles to smartphones and energy storage systems. Unlike lithium batteries, lithium-ion cells do not contain free lithium metal but instead use lithium ions and flammable electrolytes.

How Lithium-ion Batteries Work

Lithium-ion batteries have transformed the method by which we provide power to contemporary gadgets. Since their introduction by Sony in 1991, these batteries have found widespread applications. Tesla introduced the first battery-powered electric vehicle in 2008, further expanding the potential of lithium-ion batteries.

A typical lithium-ion battery pack comprises several cells arranged in modules. Each cell includes:

A cathode (positive electrode) made from lithium compounds such as Lithium Cobalt Oxide (LCO) or Lithium Nickel Manganese Cobalt (NMC).
An anode (negative electrode), usually made of graphite.
An electrolyte that allows lithium ions to move between the electrodes during charge and discharge cycles.

When the battery charges, lithium ions travel from the cathode to the anode through the electrolyte. During discharge, the ions return to the cathode, producing electrical energy.

Fire Risks Associated with Lithium-ion Batteries

While lithium-ion batteries are reliable, they pose a significant fire risk if they overheat, which can result from electrical short circuits, overcharging, rapid discharge, mechanical damage, or poor manufacturing. When this happens, a process known as thermal runaway can occur, where a chemical reaction causes the battery’s internal temperature and pressure to rise rapidly. This reaction can lead to the release of toxic, flammable gases like hydrogen fluoride, resulting in fires and explosions.

Preventing Fires with Early Heat Anomaly Detection

FLaiTek’s advanced thermal camera solutions, such as the i80 series, are designed to detect early signs of overheating in lithium-ion batteries. By identifying potential problems early, FLaiTek cameras enable operators to take action before a thermal runaway event can occur.

How FLaiTek i80 Series Thermal Cameras Prevent Battery Fires

Early Detection of Hotspots: Active thermography using FLaiTek’s i80 series thermal camera provides detailed temperature mapping across the surface of lithium-ion battery packs. This allows operators to detect small temperature anomalies, which could indicate a developing issue before it becomes critical.
Continuous Monitoring in Harsh Environments: FLaiTek thermal cameras are designed to function in extreme environmental conditions. The i80 series operates in temperatures ranging from -20°C to 2000°C, making it ideal for identifying heat anomalies in industrial and battery storage settings.
Automated Alerts and 24/7 Monitoring: FLaiTek cameras can be configured to continuously monitor battery systems around the clock. The system automatically triggers alarms when temperatures exceed predefined thresholds. This ensures that any potential issues are caught immediately, without the need for constant human supervision.
Real-Time Data and Video Streaming: FLaiTek thermal cameras can stream real-time radiometric video data, providing instant feedback to control rooms and safety personnel. This allows for immediate decision-making and ensures that battery systems are monitored at all times, even in challenging environments, such as dust-filled or smoke-polluted areas.
High-Resolution Imaging for Precision: The i80 series thermal camera provides high-resolution thermal images, which are essential for detecting even minor temperature variations. This level of precision is critical in environments where safety is a top priority.

Application of Thermal Cameras in Lithium-ion Battery Safety

FLaiTek’s thermal cameras are used in a variety of industries that rely on lithium-ion batteries, including:

Electric Vehicles: With the rise of electric vehicles, thermal cameras are essential for monitoring battery performance and preventing thermal runaway events during charging and discharging cycles.
Energy Storage Systems: As renewable energy adoption grows, lithium-ion batteries are used for large-scale energy storage. FLaiTek thermal cameras ensure these systems operate safely and efficiently.
Industrial Equipment: Many industries use lithium-ion batteries in their machinery and equipment. Early detection of heat anomalies using thermal cameras helps to avoid costly downtime and potential fire hazards.

Ensuring Safer Operations with FLaiTek Thermal Cameras

By integrating FLaiTek i80 series thermal cameras into battery management systems, companies can reduce the risk of fires, protect valuable assets, and ensure the safety of their personnel. Whether in electric vehicles, energy storage facilities, or other industrial applications, thermal imaging plays a critical role in ensuring safe battery operation.

FLaiTek thermal cameras are essential tools for detecting heat anomalies in lithium-ion batteries. By providing real-time monitoring, automated alerts, and precise temperature detection, these cameras significantly reduce the risk of thermal runaway events, making lithium-ion battery systems safer and more reliable.