Vitrek Products for Automotive & Electric Vehicle Applications

Automotive manufacturers often require specialized testing to meet safety and regulatory requirements that ensure that their vehicles comply with all relevant regulations and industry standards. Some tests include cable and harness cable testing, tire, brake and rotor testing as well as EV battery compliance requirements. By prioritizing testing and compliance solutions, manufacturers can enhance their reputation, ensure customer safety, and avoid potential legal and financial liabilities. See below for details on how Vitrek’s portfolio of solutions can support your next automotive testing requirements.

Articles & Resources for the Automotive Industry

MTI Instruments Whitepaper: Capacitance Guide to Industrial Applications

Capacitance Guide to Industrial Applications This guide from MTI Instruments explains what you need to know about using electrical capacitance for measurement in industrial applications, including advanced manufacturing. Basic Principles Capacitance is the ratio of the change in an electric charge to the corresponding change in its electrical potential (i.e., voltage). Capacitors, components that that have the “capacity” to store an electric charge, consist of conductive parallel plates that don’t touch or connect with each other. Instead, these metal plates are electrically-separated by air or a layer of insulating material [...]

  • Animation of 3 MTI Instruments capacitance sensors measuring the thickness of non-woven conductive film

Closed Loop, Non-woven Conductive Film Thickness Measurement and Control Solution

Closed Loop, Non-woven Conductive Film Thickness Measurement and Control Solution Animation showing a system setup used to measure the thickness of thin conductive films such as electric vehicle (EV) battery electrodes. Description Learn how to measure EV battery plate thickness with MTI’s Digital Accumeasure, a high-precision capacitance measurement system with nanometer accuracy and stability. Problem Lithium battery plates for electric vehicles consist of lithium ion compounds applied to either a copper plate substrate (cathode plate) or an aluminum substrate (anode plate). The plates are approximately 100-200 um thick ( .004 - .008 [...]

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Signal Generator Calibrates Strain Gauge Electronics

Signal Generator Calibrates Strain Gauge Electronics Industrial, Automotive, Transportation, Research & Development, Civil Engineering Calibration of Strain Gauge Electronics Amplitude; Bending, Tensile & Compression Description [Application Note 31218] The strain gauge has been in use many years and is the fundamental sensing element for many types of sensors, including pressure sensors, load cells, torque sensors, and position sensors. The majority of strain gauges are metallic foil types, available in a wide choice of shapes and sizes to suit a variety of applications. Foil type strain gauges feature a pattern or [...]

  • Alternating magnetic field and eddy currents

Signal Generator Simulates Eddy Current Probe

Signal Generator Simulates Eddy Current Probe Industrial, Power Generation, Automotive, Power Generation, R& D, Solar Simulation of Eddy Current Probe Gap, Amplitude, Displacement, Positioning, Thickness Description [Application Note 31218] Non-contact eddy current probes can be used to measure the position, or position change, of conductive targets in real time. Typical monitoring applications include shaft runout and/or vibration. Probe setup requires an oscillator demodulator circuit. This circuit converts the probe’s magnetic field readings into output voltages proportional to the gap between probe and target. Portal signal conditioning electronics are then used [...]

  • opposing probes in a fixture

Capacitance Sensors Track Brake Rotor Thickness Variation

Capacitance Sensors Track Brake Rotor Thickness Variation Automotive, Aviation/Aerospace Brake Rotor Testing & Manufacturing Displacement, Amplitude Description [Application Note 51018]Today’s cars and trucks offer unprecedented fuel efficiencies and handling characteristics – thanks, in part, to vehicle lightweighting. Applied to all vehicle components, lightweighting lowers stress and strain to improve mileage and boost overall performance.In keeping with this trend, today’s brake rotors are thinner and lighter than those of just a few years ago. In addition, many feature cooling vents to further improve performance. These changes, however, reduce available braking surface, forcing [...]

  • Battery Layers

Two Ways to Measure EV Battery Plate Thickness

Two Ways to Measure EV Battery Plate Thickness Animation showing a system setup used to measure the thickness of thin conductive films such as electric vehicle (EV) battery electrodes. Description Learn how to measure EV battery plate thickness with MTI’s Digital Accumeasure, a high-precision capacitance measurement system with nanometer accuracy and stability. Problem Lithium battery plates for electric vehicles consist of lithium ion compounds applied to either a copper plate substrate (cathode plate) or an aluminum substrate (anode plate). The plates are approximately 100-200 um thick ( .004 - .008 inch). [...]

  • MTI Charge Amplifier

Ideal Charge Amplifier for Piezo Electric Transducers

Ideal Charge Amplifier for Piezo Electric Transducers Aviation (Turbine Engines), Automotive Research and Development, Industrial Manufacturing Vibration Monitoring: Turbine Engines; Vehicle Testing Pressure Monitoring: Combustion Engines; Pumps, Turbines Amplitude Measurements:  Acceleration, Vibration, Pressure Description Ideal Charge Amplifier for Piezo Electric Transducers Piezoelectric-type transducers such as accelerometers used for turbine vibration measurement and pressure transducers used for combustion dynamics monitoring (CDM) produce a high-impedance charge output that must be conditioned and amplified before transmission across system cabling and into measurement instrumentation. Challenge A piezoelectric transducer is a sensor that produces a [...]

  • Measuring Non-Conductive Materials

Foam Density Measurement: Capacitance Sensors vs. Nuclear Gauges

Foam Density Measurement: Capacitance Sensors vs. Nuclear Gauges Foam Density Measurement Manufacturing EV Battery Production Thickness, Distance This application note from MTI Instruments compares two technologies for measuring foam density: capacitance sensors and nuclear gauges. It examines the basic operating principles of each technology and explains why capacitance measurement is recommended for in-line measurement during foam manufacturing. Capacitance Sensors Capacitive probes are non-contact devices that use electric fields to measure foam density. In combination with a thickness value, a density measurement may be calculated. These probes consist of a capacitance [...]

  • View of software scan pattern for silicon wafer measurement

Brake Rotors

Brake Rotors Automotive Brake Rotors Surface Description Introduction Under normal operating conditions brake rotors are subjected to extreme temperatures and forces, which can cause rotor distortion and potential failure. To make certain it can withstand these conditions; extensive laboratory testing is performed to optimize design for longevity, short stopping distance, and vibration free operation. Extensive on-vehicle testing is done under real life conditions to test prototype units and engineering designs. Test vehicles are driven for long periods of time while brake performance is monitored by a variety of sensors and data [...]

  • Tire Tread

Tire Tread Measurement

Tire Tread Measurement Automotive Tire Tread Inspection Depth Description Tire manufacturers and Used Tire Reuse Centers want to satisfy their customers, and protect themselves from liabilities. Manufacturers are moving to 100% tire inspection for tread depth, defects and abnormality detection. Defects not only cause potential safety issues but they can also introduce unwanted vibration into the vehicle suspension system and cause excessive road noise. Belts can be overlapped, or not cover the complete tire surface, causing weak or bubbled areas and imbalances. The tread depth can be too shallow, leading [...]

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Tire Tread Measurement with 2D Laser

Tire Tread Measurement with 2D Laser Automotive Tire Tread Measurement with 2D Laser Depth Description To ensure customer safety and extend product life, tire manufacturers are moving to 100% tire inspection. This QTM strategy includes tread depth measurement and defect detection. Shallow tread depths shorten service life while defects such as blistering, bubbles, and overlapping belts can lead to runout, road noise, vehicle suspension vibration or worse – catastrophic failure. Problem Many of today’s all-season tires feature asymmetrical tire tread patterns. Designed to meet the conflicting requirements for dry grip [...]

  • Manufacturing

Windshield Manufacturing

Windshield Manufacturing Automotive Windshield Manufacturing Tolerances Description In order to maintain proper profile and thickness within a glass furnace the extrusion plate spacing must be maintained at a predetermined gap. Unfortunately, due to process changes and temperature swings this gap can fluctuate significantly in short periods of time. This variation causes the glass thickness to change (check out our glass thickness measurement devices to accurately measure thickness), producing uneven temperature gradients and creating potentially weak glass panels. To control this critical parameter the manufacturing process requires automated active feedback control [...]

Thread Checking

Automotive Thread Checking Presence/Absence Description Manual thread inspection is slow, not always reliable and tedious for the inspector. Manufacturers have struggled to come up with ways to reliably automate the process at a reasonable cost. Automated systems are available that use “screw sensors” can quickly wear or be cross threaded, requiring operator attention and a tooling change. A worn screw can provide false rejections leading to the unnecessary scrapping of parts. Capacitance solutions are cost effective alternative which are becoming increasingly popular due to their high reliability and fast [...]

  • Press

Spindle Run Out

Spindle Run Out Automotive Spindle Run Out Distance Description Rotating targets frequently have an intermittent, uncertain or nonexistent ground path. This introduces unwanted noise, instability, drift and reduces accuracy of the measurement. MTI Instruments offers a unique "Push-Pull" capacitance measurement system that does not require a grounded target. It utilizes two probes, built into one body, that work together to complete the ground path. One probe pushes current into the brake rotor while the adjacent probe pulls the current out. The result is a "clean", consistent electrical sensing path. As [...]

  • Manufacturing

Grinding Process

Grinding Process Automotive Grinding Process Surface Description A cylindrical grinding process finishes most wheel spindle surfaces. It is essential that this grinding process leave a surface finish that is smooth and free of defects with minimal runout. No grinder produces a perfect surface. Grinder wheel runout, improperly dressed wheels and fixture vibrations can cause chatter on the spindle surface finish. Chatter is a series of microscopic, repetitive imperfections, or waves, in the surface of the material being machined. The required production environment sensor must have small spatial resolution, high frequency [...]

  • Oil in liquid

Oil Film Thickness Measurement

Oil Film Thickness Measurement Automotive Oil Film Level Description A top marine engine manufacturer commissioned MTI Instruments to design and manufacture a non-contact sensor to measure the microscopic oil film layer between the engine cylinder wall and the piston ring. Engine testing is normally performed through a range of low RPM's to high RPM's (400- 6000) with piston linear speeds approaching 500 inches/second and at various torques. A measuring system with high frequency response and small sensor size was essential to keep engine machining to a minimum while not altering the [...]

  • Nut

Brake Rotors Thickness Variation

Brake Rotors Thickness Variation Automotive Brake Rotors Thickness Variation Surface Description Introduction Driving cross country or cross town, we give little thought to the operation or complexity of our vehicle braking systems. They only cross our mind when we absolutely need them; we never stop to think about the extensive design and testing that makes them such a lifesaver. Take the brake rotor for example. Under normal operating conditions it's subjected to extreme temperatures and forces, which can cause rotor distortion and potential failure. To make certain it can withstand these [...]

  • Fan

Torque Converter

Torque Converter Automotive Torque Converter Surface Description Since minute defects in the torque converter casing wall thickness can result in unacceptable and dangerous torque converter expansion, a precision measurement system was needed to measure the impeller hub displacement and thus the torque converter axial displacement. An AC dynamometer would be required to spin the torque converter at a high rate of speed while a fast response hydraulic system is needed to pressurize the converter to pressures up to 150 psi. MTI’s MicroTrak laser sensor was selected because it offered a [...]

  • Manufacturing

Thermal Expansion On Automobile Engine

Thermal Expansion On Automobile Engine Automotive Thermal Expansion On Automobile Engine Dimensions Description For years the sole purpose of the oil pan was to act as a reservoir for the engine lubricant. Some modern engines now utilize the pan as a structural component. It is machined from a rigid steel or aluminum casting and designed to support the lower portion of the crankshaft bearings and rear main seal. This development has introduced a potential problem area that must be analyzed. As engines go through heating and cooling cycles it is [...]

  • Manufacturing

Sheet Metal Monitoring

Sheet Metal Monitoring Automotive Sheet Metal Monitoring Thickness Description Introduction: When sheet metal is formed in a continuous process it needs monitoring during the actual feed prior to machining or forming to prevent defects and scrap.  One way to accomplish this is to use a laser sensor to measure the thickness. Problem: A major electrical equipment manufacturer needed a way to monitor the incoming material just prior to shearing and forming. The device needed to be robust, non-contact, reliable, accurate, and fast. The client would be using their data acquisition [...]

  • Tire Tread

Tire Tread Inspection With 1D Laser Sensor

Tire Tread Inspection With 1D Laser Sensor Automotive Tire Tread Inspection With 1D Laser Sensor Depth Description Tire manufacturers wants to satisfy their customers, and protect themselves from liabilities, manufacturers are moving to 100% tire inspection for defects and abnormalities. Defects not only cause potential safety issues but they can also introduce unwanted vibration into the vehicle suspension system. Belts can be overlapped, or not cover the complete tire surface, causing weak or bubbled areas and imbalances. The tread depth can be too shallow, leading to decreased service life. An [...]

  • EV Battery Plate Thickness

Case-In-Point: Step Height Measurement (Thickness) of Copper Foil or EV Battery Film on a Roller Rig

Step Height Measurement (Thickness) of Copper Foil or EV Battery Film on a Roller Rig Leverage MTI Instruments’ digital Accumeasure system to measure the thickness of the material used as anode and cathode plates in rechargeable Li-Ion battery cells Many roll-to-roll finishing processes typically use a calender, or series of hard pressure rollers, to deliver smooth, high-quality products of plastic, textile, or paper (Fig 1). Ensuring a consistent material thickness, however, depends on the ability to monitor, and maintain, a precise gap between rollers. This application note describes a quick and easy means for roller gap measurement. Introduction [...]

New Video from MTI! Closed-loop System to Monitor and Control Conductive Film Thickness During Manufacturing

Closed-loop System to Monitor and Control Conductive Film Thickness During Manufacturing This animation demonstrates how Accumeasure with capacitance probes can be used as a solution to measure and control conductive film thickness in a production line where these measurements can be fed back to a controller which adjusts the roller(s) to increase or decrease the gap to keep the film’s thickness within specification. The MTI Instruments Capacitive system has greater than 100 nm resolution and 1um accuracy. This solution is appropriate for measuring the following: EV battery plate thickness Non-woven conductive material thickness Conductive film thickness Roll-to-roll conductive [...]

TORQUE CONVERTER

Industry Automotive Applications Torque Converter Measurement Type Surface Description Since minute defects in the torque converter casing wall thickness can result in unacceptable and dangerous torque converter expansion, a precision measurement system was needed to measure the impeller hub displacement and thus the torque converter axial displacement. An AC dynamometer would be required to spin the torque converter at a high rate of speed while a fast response hydraulic system is needed to pressurize the converter to pressures up to 150 psi. MTI’s MicroTrak laser sensor was selected because it offered [...]

CAPACITANCE SENSORS TRACK BRAKE ROTOR THICKNESS VARIATION

[Application Note 51018]Today’s cars and trucks offer unprecedented fuel efficiencies and handling characteristics – thanks, in part, to vehicle lightweighting. Applied to all vehicle components, lightweighting lowers stress and strain to improve mileage and boost overall performance.In keeping with this trend, today’s brake rotors are thinner and lighter than those of just a few years ago. In addition, many feature cooling vents to further improve performance. These changes, however, reduce available braking surface, forcing automotive engineers to consider alternative materials and designs. Problem Because the extreme temperatures and forces generated during braking can easily lead to rotor distortion and failure, [...]

Windshield Manufacturing

Industry Automotive Applications Oil Film Measurement Type Level Description In order to maintain proper profile and thickness within a glass furnace the extrusion plate spacing must be maintained at a predetermined gap. Unfortunately, due to process changes and temperature swings this gap can fluctuate significantly in short periods of time. This variation causes the glass thickness to change (check out our glass thickness measurement devices to accurately measure thickness), producing uneven temperature gradients and creating potentially weak glass panels. To control this critical parameter the manufacturing process requires automated active feedback [...]

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BRAKE ROTORS THICKNESS VARIATION

Industry Automotive Applications Brake Rotors Thickness Variation Measurement Type Surface Description Driving cross country or cross town, we give little thought to the operation or complexity of our vehicle braking systems. They only cross our mind when we absolutely need them; we never stop to think about the extensive design and testing that makes them such a lifesaver. Take the brake rotor for example. Under normal operating conditions it’s subjected to extreme temperatures and forces, which can cause rotor distortion and potential failure. To make certain it can withstand [...]

OIL FILM THICKNESS MEASUREMENT

Industry Automotive Applications Oil Film Measurement Type Level Description A top marine engine manufacturer commissioned MTI Instruments to design and manufacture a non-contact sensor to measure the microscopic oil film layer between the engine cylinder wall and the piston ring. Engine testing is normally performed through a range of low RPM’s to high RPM’s (400- 6000) with piston linear speeds approaching 500 inches/second and at various torques. A measuring system with high frequency response and small sensor size was essential to keep engine machining to a minimum while not altering [...]

  • spindle run-out measurement

SPINDLE RUN OUT

Industry Automotive Applications Spindle Run Out Measurement Type Positioning Description Rotating targets frequently have an intermittent, uncertain or nonexistent ground path. This introduces unwanted noise, instability, drift and reduces accuracy of the measurement. MTI Instruments offers a unique “Push-Pull” capacitance measurement system that does not require a grounded target. It utilizes two probes, built into one body, that work together to complete the ground path. One probe pushes current into the brake rotor while the adjacent probe pulls the current out. The result is a “clean”, consistent electrical sensing path. As [...]

THERMAL EXPANSION ON AUTOMOBILE ENGINE

For years the sole purpose of the oil pan was to act as a reservoir for the engine lubricant. Some modern engines now utilize the pan as a structural component. It is machined from a rigid steel or aluminum casting and designed to support the lower portion of the crankshaft bearings and rear main seal. This development has introduced a potential problem area that must be analyzed. As engines go through heating and cooling cycles it is essential that the engine block and oil pan expand and contract at nearly the same rate. If not, stresses can be introduced [...]

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BRAKE ROTORS

Industry Automotive Applications Brake Rotors Measurement Type Surface Description Under normal operating conditions brake rotors are subjected to extreme temperatures and forces, which can cause rotor distortion and potential failure. To make certain it can withstand these conditions; extensive laboratory testing is performed to optimize design for longevity, short stopping distance, and vibration free operation. Extensive on-vehicle testing is done under real life conditions to test prototype units and engineering designs. Test vehicles are driven for long periods of time while brake performance is monitored by a variety of sensors [...]

Case-In-Point: High-Accuracy Capacitive Thickness Measurement Optimizes Li-Ion EV Battery Plate Qualities

High-Accuracy Capacitive Thickness Measurement Optimizes Li-Ion EV Battery Plate Qualities EV Battery manufacturers need to measure EV battery plate thickness with a high degree of precision (repeatable <2um accuracy and resolution) to optimize manufacturing efficiencies while maintaining uniform cell capacity and minimizing waste. The MTI Accumeasure System provides an effective means of monitoring plate thickness achieving sub 2um accuracy with high repeatability Introduction The rapidly expanding demand for electric vehicles is driving advances in the production of rechargeable cells that comprise the first stage in the composition of EV battery packs. Individual Li-Ion cells are combined to [...]

GaGe Whitepaper: Real-Time High-Speed Data Acquisition on PC-Based System Platforms

GaGe Whitepaper: Real-Time High-Speed Data Acquisition on PC-Based System Platforms By Gerald Allgaier, Systems Specialist and Bob Fitzgerald, Application Specialist - Vitrek For many measurements that require the capture and processing of analog data, data throughput speed and conversion resolution are the two most important considerations. Typical examples include Radar, Signals Intelligence (SIGINT), Ultrasound Imaging, Non- Destructive Testing (NDT), Mass Spectroscopy / Time-of-Flight (TOF), and Production Test. These test applications usually demand high speed data transfer rates. So typically, Digitizers (A/D) or Arbitrary Waveform Generators (D/A) residing on a high-speed backplane are required. These [...]

  • Man performing electrical tests on a new car

Why You Need Automotive Cable Tests Before Cars Hit the Road

The automotive industry deals with some of the most technologically diverse pieces of commercially available machinery worldwide — cars and trucks. As these machines continue to evolve and the technology under the hood becomes more complex, ensuring that every wire, electrical connection, and more meets the strict safety standards remains a high point of emphasis.  […]

Cable Testing Applications

Vitrek Products for Cable Testing Applications Cable/Wire Testing Overview Cable testing is important in any industry that relies on cables for its operation. Cable testing is important for compliance and regulations because it helps ensure that cables meet the necessary requirements and standards set by regulatory bodies or industry organizations. These requirements are in place to promote safety, reliability, and performance, and failure to comply can result in legal consequences or penalties. Cable testing is important in various industries, including: Telecommunications: Cable testing is essential in the telecommunications industry to ensure that cables are [...]

MTI’s Wireless Gap Measurement Probe System Is Ideal for Rotating Machinery

The Accumeasure capacitance probe system offers major improvement over conventional eddy current probes; network up to four probes per system to  deliver rich geometrical in-situ measurements in a variety of industry standard formats. Albany, NY—June 28, 2022—MTI Instruments, a US-based manufacturer of advanced test and measurement equipment, announces the introduction of its Accumeasure Wireless Gap Measurement Probe System. The system consists of up to four, battery-powered, wireless capacitance probes paired via Bluetooth to their receiving device. The wireless capability and compact form factor of the battery-powered probes are designed specifically to measure gap in difficult-to-reach or [...]

Press Release: MTI’s Wireless Gap Measurement Probe System Is Ideal for Rotating Machinery

The Accumeasure capacitance probe system offers major improvement over conventional eddy current probes; network of up to four probes delivers rich geometrical in-situ measurement   Albany, NY—June 28, 2022—MTI Instruments, a US-based manufacturer of advanced test and measurement equipment, announces the introduction of its Accumeasure Wireless Gap Measurement Probe System. The system consists of up to four, battery-powered, wireless capacitance probes paired via Bluetooth to their receiving device. The wireless capability and compact form factor of the battery-powered probes are designed specifically to measure gap in difficult-to-reach or inaccessible locations. Unlike eddy current probe systems, [...]

Vitrek’s Automated Testing System Simplifies and Speeds Automotive Cable/Harness Testing

Vitrek's Automated Testing System Simplifies and Speeds Automotive Cable/Harness Testing Testing system combines a hipot tester with Vitrek’s 964i switching system and QT Enterprise software; the automated approach enables manufacturers to configure tests easily and access historical data Introduction With 20 or more harnesses, many interfacing with digital control devices, today's vehicles have increasingly complex electronic systems. Precise and accurate continuity and cable testing must be performed on every connection during the assembly process to assure safety and reliability in the application. This article presents a highly functional, automated approach to automotive/cable harness testing. It [...]

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High Precision Portable Signal Generators and Calibrators: Everything You Need to Know

High precision portable signal generators are portable electronic devices that generate highly precise signals for testing, system calibration, sensor simulation, troubleshooting, and monitoring. Unlike the benchtop signal generators that are used in laboratories, these hand-held portable devices are designed to be used in the field. The best high precision portable signal generators are also rugged and NIST traceable, meaning that their manufacturer calibrates them to standards from the National Institute of Standards and Technology (NIST). In terms of cost, high precision portable signal generators are more expensive than less precise, lower-end devices that can be held in the hand; [...]

MTI Instruments Enters Advanced Qualification Stage for Electric Vehicle Battery Measurement Device with Several Major Automotive OEM Manufacturers

NEW YORK, December 16, 2021 –  MTI Instruments division, a manufacturer of precision tools and testing equipment for electronics, aviation, automotive, power and other industries, today announced that it has entered into the advanced qualification stage for its electric vehicle (EV) battery measurement device with several major automotive OEM manufacturers.  Moshe Binyamin, President and CEO of MTI Instruments commented, “We committed to shareholders that we would communicate with them as we began to get traction in the growing and large EV Battery manufacturing segment. I am pleased to report, we are gaining serious traction.” Binyamin further added, “In fact, [...]

Webinar Recap: Vitrek Electrical Safety Testing for the Automotive Industry

Vitrek is a leading provider of testing solutions for electrical safety across multiple industries. Headquartered in San Diego, CA, and in business for over three decades, Vitrek has established itself as one of the premier electrical safety testing companies on the market. They serve over 30 different countries and provide electrical safety testing equipment that can be utilized in countless applications. […]

Silicon Carbide vs. Silicon in EV Power Electronics

Compare silicon carbide vs. silicon for electric vehicle (EV) power electronics and learn about SiC wafer measurement. As demand for electric vehicles (EVs) continues to grow, manufacturers are comparing two semiconductor technologies, silicon carbide and silicon, for power electronics applications. Silicon carbide (SiC) provides the high temperature resistance, low power consumption, rigidity, and support for smaller, thinner designs that EV power electronics need. Examples of SiC’s current applications include on-board DC/DC converters, off-board DC fast chargers, on-board battery chargers, EV powertrains, and automotive lighting for LEDs. According to Automotive World, SiC technology could also drive future EV innovations [...]

EV Batteries Need Thickness Gauging for Lower Costs and Higher Performance

EV batteries need to cost less and last longer. Until the e-mobility industry solves these challenges, electric vehicle (EV) adoption won’t match the hype that’s driven by Tesla, the established automakers, and a host of startups who are attracting investors. According to Axios, the expense of owning an electric vehicle will exceed that of owning a conventional one until EV batteries cost less than $100/KWh to produce. Unfortunately, the EV industry isn’t expected to hit that target for another ten years. Yet, there is some encouraging news. Less expensive and better performing EV batteries are just a few years [...]

How to Measure Dielectric Separator Thickness in EV Batteries

The International Energy Agency predicts that as many as 125 million electric vehicles (EVs) will be on the road by 2030. At the heart of these electric cars, trucks, and buses is the lithium-ion (Li-ion) battery, a type of rechargeable battery with high energy density and low self-discharge. The plates in Li-ion batteries consist of lithium compounds that are applied to either a copper plate substrate (cathode) or an aluminum substrate (anode). In turn, these two plates are separated by a dielectric separator. All of the layers in an EV battery are extremely thin. In fact, the cathode and [...]

  • EV batteries

Capacitance Sensing Provides Two Ways to Measure EV Battery Plate Thickness

MTI Instruments has released an application note that explains how to use capacitance to measure the thickness of the lithium battery plates in electric vehicles (EVs). Manufacturers need to check these plates for thickness before calendaring them together to ensure that the overall battery diameter is within specifications. In EV batteries, lithium ion compounds are applied to either a copper plate substrate (cathode) or an aluminum substrate (anode plate). These conductive plates are separated by a dielectric. MTI Instruments, a global supplier of precision measurement solutions, makes capacitance sensors that can measure thicknesses materials down to nanometers. Moreover, MTI [...]

Product Education & Training

Education & Training Vibration Measurement & Engine Rotor Balancing High-Speed Data Acquisition Products for Streaming Applications Industry Application Webinars Test & Measurement Solutions for Semiconductor Manufacturers GaGe Digitizers in Ultrasonic Applications Electrical Safety & Compliance Testing for Printed Circuit Board Manufacturers Vitrek Products for Metrologists & Calibration Labs Vitrek Electrical Safety Testing for the Appliance & Consumer Product Industries Compliance Testing for the Lighting Industry Webinar [...]

White Paper: Cable & Connector Test System Facilitates Multi-Point High Voltage/Current Testing

White Paper: Cable & Connector Test System Facilitates Multi-Point High Voltage/Current Testing Introduction Hipot testing is critical in assuring compliance with a host of electrical safety standards and in confirming the assembled product is free from electrical or mechanical defects. Hipot testers are used to measure leakage current and insulation resistance between all components and connections, confirm solid ground connections and test ground bonds. All of these tests require the sequential application of precise and controlled high voltages or currents between pairs of elements then accurately measuring and recording the results. Products like the Vitrek 95x and V7x series [...]

  • MTI 2100 Fotonic Sensor | Fiber Optic Sensor

Position, Displacement, and Vibration Measurement with Precision, High Resolution, and Flexibility

The MTI-2100 Fotonic™ sensor uses advanced fiber optics and electronics to precisely measure position, displacement, and vibration. This high-resolution, non-contact metrology system supports a wide range of interchangeable fiber-optic probes and works with almost any surface, including metallic, composite, plastic, glass, ceramic, or liquid. Made in the USA by MTI Instruments, the MTI-2100 Fotonic™ features a modular design and supports application-specific requirements in R&D, quality, and process control. With its dual channel capabilities, the MTI-2100 Fotonic™ sensor allows users to make simultaneous measurements, such as for structure dynamics and modal analysis. All probe modules have two distinct operating ranges [...]

  • Keys to resiliency in MRO

How the Aviation Industry Solves Vibration and Balancing Challenges

The aviation industry spends significant amounts of time and money on problems caused by engine vibration. Imbalance, the most common cause of engine vibration, happens because of bird strikes and other impacts, but also because of natural wear and corrosion that redistribute mass. In turn, out-of-balance parts can result in cabin noise, metal fatigue, and cracked turbine, fan, or compressor components. In the most extreme cases, catastrophic engine failure may result MTI Instruments, a worldwide supplier of precision measurement solutions, makes equipment for monitoring vibration levels and balancing rotors. For maintenance, repair and overhaul (MRO) crews who want to [...]

Common Test and Calibration Uses of the 1510A Portable Signal Generator

Powerful Ways the Portable 1510A Can Be Used In The Field As one of the most versatile and powerful hand-held signal generators on the market, the 1510A is a two-channel, battery-powered, microprocessor-controlled direct digital signal generator. It has an average battery life of 3 hours of continuous use. Weighing in at under two pounds, makes it ideal for use in the field. There are many different ways this sophisticated device can be leveraged to perform precise test and calibration of equipment, wires, cables, sensors and much more. Use Case #1 | Sensor Simulation [...]

Capacitance Guide for Industrial Applications

Accumeasure Digital Capacitance System D Series Gen 3 View Product Capacitance Displacement and Gap Measurement Probes View Product Accumeasure Analog Capacitance System View Product Basic Principles Capacitance is the ratio of the change in an electric charge to the corresponding change in its electrical potential (i.e., voltage). Capacitors, components that that have the “capacity” to store an electric charge, consist of conductive parallel plates that don’t touch or connect with each other. Instead, these metal plates are electrically-separated by air or a layer of insulating material (i.e., the dielectric). MTI’s technology [...]

  • Brake Rotor Thickness Variation

Measuring Brake Rotor Thickness Variation with Capacitive Sensing

Brake rotor thickness variation, or disc thickness variation (DTV), causes uneven wear to brake rotors, disc-shaped automotive parts that are squeezed between brake pads to slow or stop a vehicle’s wheels. When a brake rotor has areas of different thickness, the amount of clamping force that’s applied across the rotor’s surface varies. These differences in clamping force lead to difference in torque, and the results may include brake shuddering, pulsating, or vibration. Even under normal driving conditions, brake rotors are subjected to extreme conditions that can cause performance-related issues. To ensure that brake rotors can perform properly without problems such [...]

  • Fiber Optic Sensors

Fiber Optic Sensors Help Stop Subway Shutdown

Fiber optic sensors will help keep commuters moving between Manhattan and Brooklyn this year and beyond. Recently, New York Governor Andrew Cuomo announced that New York City’s Metropolitan Transit Authority (MTA) would not close the L train tunnel for a planned 15-month repair project. Instead, the MTA will use technology-driven solutions to keep the tunnel open and operational for weekday riders. In a joint statement, a panel that included engineering experts from Columbia and Cornell explained that "The L Train Tunnel project gives us the opportunity to integrate technologies and methods that have never been used before in a [...]

What is a displacement sensor?

What are Displacement Sensors (Displacement Gauges) and Dimension Measurement Systems? What is a displacement sensor? A displacement sensor (displacement gauge) is primarily used to measure the range of where an object has to travel and in relation to a reference position. Displacement sensors have multiple uses. Its primary use is for dimension measurement to figure out an object’s width, height, and thickness. Accuracy, application and usage environment is required when selecting the best equipment. What is a measurement sensor? A measurement sensor is a device that is used to measure an object to ascertain its dimensions such as by [...]

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Selecting a Displacement Sensor / Measuring System

Capacitive displacement sensors Capacitive displacement sensors are non-contact devices that are used for measurements at a high-resolution. It can also be used to check the position of any conductive object as well as measure the width or density of non-conductive materials. Capacitive displacement sensors have a large variety of uses including precision thickness measurements, assembly line testing, assembly metrology, and semiconductor processing. Capacitive displacement sensors can be found in manufacturing facilities all around the globe. There’s more to selecting the proper type of displacement sensor and measurement system than meets the eye. To select the appropriate type of device [...]

Target Material and Characteristics

Target Material and Characteristics Transparent/Opaque Targets There are a number of measurement systems that are capable of measuring a target that is opaque. When it comes to transparent targets, the measurement system being used must match the material of the target being measured. For example, if you’re attempting to measure plastic you should use a contact-type measurement system such as a micrometer. When performing a soft target measurement, such as film, a non-contact measurement system (such as a laser displacement sensor) should be utilized. Hard/Soft Targets Objects made out of hard material (such as a block of wood), would [...]

What is Measurement?

Measurement is about determining the quantifiable attributes of a target object. Examples of these attributes include: length weight distance thickness position capacity size The following sections explain more about what measurement is – and isn’t. Why is measurement misunderstood? Sometimes, people use the term “measure” instead of “calculate” or “quantify”. All these terms are related, but they’re not the same. For clarity’s sake, think of measurement as a single action that you perform with instrumentation. Collectively, “instrumentation” describes devices (i.e., instruments) that measure, indicate, and sometimes record values. Today, there are many different types of specialized measuring instruments. Bakers [...]

MICROTRAK 4: 1D Laser Displacement Sensor

Accurate and repeatable displacement measurements from highly reflective to dull surfaces Request a Quote Download Microtrak 4 Brochure Compact digital laser displacement sensor head with stable and accurate measurements The latest 1D laser displacement sensor from MTI provides excellent speed and accuracy for even the most difficult applications and provides data output and power through a single USB cable. The MicroTrak 4 is the ultimate 1D laser sensor for measuring height, thickness, displacement, vibration, and more, with a sensor frame rate of 40k Samples/sec. and linearity of 0.03% FSO (Full Scale Output) accuracy and [...]

  • Microtrak 3 Laser Displacement Sensor

MICROTRAK 3: 1D Laser Displacement Sensor

An essential measurement tool for process automation, quality control and tool automation control. Request Quote Download Brochure Compact laser triangulation sensor head for easy integration to machine control system High resolution, high speed laser displacement sensor (non-contact linear displacement sensor) utilizes the latest CMOS sensor technology that challenges even the most difficult measurement applications. The Microtrak™ 3 is an essential measurement tool for process automation, quality control and tool automation control, for applications such as, thickness measurement, dimensional displacement, part profiling, vibrations testing, build-up measurement, and much more. Measurement rate [...]

ProTrak HD: 2D/3D Laser

Accurate Long Range Non-contact Laser Sensor for 2D and 3D profiling Download Brochure Request a Quote Accurate Long Range Non-contact Laser Sensor for 2D and 3D profiling The ProTrak HD long range profiling laser displacement sensor is built to satisfy the most demanding automated dimension, angle, curvature and height in the industrial application. At a fast speed of 6,000 frames per second and up to 2.5µm resolution, it also has measuring of up to 800 mm. 1 gigabit per second transfer rate 6,000 frames per second TCP/IP GbE Built-in display and [...]

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