Nondestructive Analysis of Automotive Parts Used in Advanced Driver-Assistance Systems (ADAS)

Significance of the topic

Automotive advanced driver assistance systems ADAS rely on sensors such as millimeter wave radar and wide angle cameras mounted on the vehicle exterior. Ensuring the internal integrity of these components and their housings is crucial for safety and reliability. Nondestructive 3D analysis through X ray CT and qualitative material identification via infrared microscopy enable comprehensive assessment of internal structures adhesives and resin materials used in sensor modules.

Objectives and overview of study and article

This work aims to demonstrate the capabilities of a microfocus X ray computed tomography system and an infrared microscope for nondestructive evaluation of ADAS sensor parts. Two case studies are presented. First the internal geometry voids and assembly angles of a millimeter wave radar module are examined. Second the fixation and installation angle of an onboard automotive camera are assessed. Additionally the chemical composition of resin housings and adhesive materials is characterized.

Methodology and Instrumentation

• X ray CT System inspeXio SMX 225CT FPD HR Plus microfocus CT system for 360 degree transmission scanning and 3D reconstruction. Resolution approximately 50 micrometers enabling void detection and dimensional measurements
• Infrared Microscope IRTracer 100 and AIMsight infrared microscope for qualitative analysis. ATR method with diamond cell used for crushed radar resin. Measurement conditions include 8 cm minus1 resolution 45 scans apodization SqrTriangle and mapping aperture of 10 by 30 micrometers

Main results and discussion

The CT analysis of the radar antenna revealed cross sectional dimensions of 0.380 0.367 and 0.372 millimeters and allowed precise length measurements between antenna elements. Three dimensional void mapping of the adhesive sealing the radar internals displayed void volumes in color enabling quantitative evaluation before and after thermal shock tests. For the automotive camera CT cross sections demonstrated secure fixation by adhesive and screws. The camera lens axis installation angle of 18 degrees relative to the case bottom and 90 degrees to a reference axis was confirmed.
Infrared microscopy identified the radar housing resin as polybutylene terephthalate PBT. Transparent fibers detected in the sample matched silica confirming glass fiber reinforcement. The camera housing resin was identified as an epoxy resin offering high mechanical stiffness and water resistance.

Benefits and practical applications of the method

• Non destructive evaluation of internal structure voids and component alignment in assembled sensor modules
• Quantitative measurement of dimensions angles and void volumes for design verification and quality control
• Material identification of resins adhesives and additives to support material selection and failure analysis

Future trends and potential applications

Advances in X ray CT detector technology and image processing promise higher resolution faster scanning and automated defect detection powered by artificial intelligence. Integration of 4D CT for time resolved studies of thermal cycling and mechanical stress will enhance durability evaluations. Combining chemical mapping by infrared and X ray fluorescence microscopy may yield more comprehensive multimodal characterization of complex sensor assemblies.

Conclusion

The combined use of microfocus X ray CT and infrared microscopy provides a powerful nondestructive toolkit for evaluating internal features material composition and assembly quality of ADAS sensor components. These methods support reliable design benchmarking manufacture and durability testing without disassembly or destruction of critical parts.

Reference

Maruyama K Sato W Nondestructive Analysis of Automotive Parts Used in Advanced Driver Assistance Systems Application News Shimadzu Corporation First Edition Mar 2024