Thermal imaging scan
FLIR heat-map of battery, motor, charger under load.
A FLIR thermal imaging scan of an EV under load is the fastest non-invasive way to find weak cells, failing inverter switches, hot DC connectors, and motor-housing anomalies. Heat is the first symptom of nearly every electrical fault. We capture annotated thermal images at multiple operating points and hand you a comparative report.
What's included
- Battery pack thermal sweep
- Motor + housing scan
- Inverter thermal map
- Charge-port + DC busbar check
- Annotated thermal image report
Why this matters
Most cell failures show as a temperature anomaly weeks before they show as a capacity drop. Same with DC busbar joints — a hot junction means a high-resistance connection that's eating range and risks arcing.
How it works
- 1
Cold baseline scan (vehicle off, 1 hour rest).
- 2
Under-charge scan during a 5kW pull.
- 3
Under-load scan during a controlled drive.
- 4
Annotate hotspots, compare against OEM expected temperature maps.
- 5
Written verdict with photos.
What to expect
Allow 60 minutes. Final report includes thermal images annotated with delta-T from neighbouring cells/components. Findings valid 30 days.
What we typically find
From hundreds of inspections — what makes the report.
- 1-2 cells running 4-8°C hotter than neighbours (early-stage weak cell)
- Charge-port pin running hot (worn or corroded contact)
- DC busbar joint warm (re-torque recommended)
- Motor housing hot on one side (bearing wear)
How to prepare
- Don't fast-charge in the 4 hours before the scan (we need a real cold baseline)
- Bring vehicle with 50-70% SoC
Equipment we use
- FLIR E96 thermal camera (0.04°C sensitivity)
- Controlled charge bench
- Drive route with consistent load profile
Certifications
- FLIR-certified thermographer on staff
- 30-day finding validity
Transparent pricing breakdown
No hidden charges. This is exactly what makes up your bill.
Bench time (60 min) | ₹1,800 |
Multi-state thermal capture + annotation | ₹1,199 |
| Total | ₹2,999 |
What customers say
“Found my charging port pin was running 30°C hotter than the others. Cleaned it, charging is back to spec.”
“Thermal images made it obvious which cell was the problem. Went into the cell-level diagnostic with a head start.”
FAQs
Does the EV need to be running?+
Yes — we test under load + under charge.
How long?+
1 hour.
Will it find a bad cell?+
Often yes — thermal anomalies usually correlate with weak cells.
Who needs this
Owners reporting hot spots after charging, range loss in summer, or post-fast-charge events.
Related services
Ready to book thermal imaging scan?
Fixed price ₹2,999 — no surprises. Or describe a different problem and we'll match the right service.