skip to Main Content
Future Electric Vehicle Platforms Will Be Flexible And Multifaceted

Future Electric Vehicle Platforms Will be Flexible And Multifaceted

As the automotive industry converges toward connected, autonomous, shared, and electric (CASE) mobility, original equipment manufacturers (OEMs) are working on re-engineering their conventional platforms to accommodate electric vehicle (EV) components such as batteries and motors. However, the industry’s transition from a vehicle-centric to a service-centric approach necessitates the development of new digital platforms (software, back-haul connectivity, and cloud).

Frost & Sullivan’s recent analysis finds that future modular EV platforms will be flexible and multifaceted, with various vehicle types and shapes built on a single program, saving OEMs the time, effort, and money required to launch new models. The study examines emerging market trends, platform development’s collaborative approach, new business models for platforms, and growth opportunities.

“In the future, the automotive industry will not be restricted to traditional vehicle manufacturing methods, and sales will focus on building new downstream sources of revenue with an emphasis on the users instead of the vehicles,” said Kamalesh MohanarangamProgram Manager, Mobility Practice at Frost & Sullivan.

“As the automotive industry shifts from the traditional pyramidal value chain to a flat value chain, mobility companies are sourcing chassis technology and platforms from third parties and integrating their technologies.”

Mohanarangam added: “Although the initial investment required to develop a dedicated, scalable platform is significantly high, the excessive flexibility this platform offers will offset this investment through economies of scale. Further, the amount of time, investment, and effort required to manufacture different battery electric vehicles (BEVs) on an EV platform is significantly less when compared to other platforms.”

Market participants should focus on the following growth prospects:

  • To overcome CASE-related challenges, industry participants must develop modular and flexible platforms to offer a number of models without significant investment.
  • With electrification and autonomy gaining popularity, OEMs need to push purpose-built platforms for EV production to enable the seamless introduction of automation.
  • Suppliers will need to expand their scope and focus on bringing in X-by-wire systems for spacious cabins. They should ensure that fail-operational functionalities are built into the system to develop and offer products that address evolving hardware architecture and the software consolidation process.
  • By developing end-to-end software platforms that are scalable and modular, OEMs can make resource sharing a reality, which will lower overall costs and add new capabilities.

 

Check these articles out:

Schaeffler Takes Over Compact Dynamics

Hyundai Motor And Singtel Collaborate To Advance Singapore’s Smart Mobility Ecosystem And Industry 4.0 Journey

The Auto Industry: Roadmap To The Future

Toyota Strengthens Automotive Production Amidst Challenging Year

Automotive Manufacturing Developments In Southeast Asia Amid COVID-19

 

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

TRUMPF Commits To E-Mobility And Sustainable Battery Production

TRUMPF Commits To E-Mobility And Sustainable Battery Production

The TRUMPF Group’s corporate venture capital unit has acquired a minority stake in the US start-up Battery Resourcers. Headquartered in Worcester, Massachusetts, Battery Resourcers has developed an efficient and eco-friendly process for recycling lithium-ion batteries. Unlike conventional methods that start by breaking down batteries into their separate chemical components, this new approach directly synthesizes new battery-ready cathode active materials from spent lithium-ion cells.

“The new recycling process developed by Battery Resourcers enhances the sustainability of e-mobility. It keeps scarce resources available in the circular economy, cuts the cost of manufacturing new battery cells, and saves energy in the production process,” says Dieter Kraft, Managing Director of TRUMPF Venture. The new technology recovers 97 percent of the metals contained in the battery cell, reducing cathode cost by 35 percent which compares well to manufacturing a new cell from virgin material. It also reduces production emissions by around 32 percent and energy consumption by 13 percent.

Lithium-ion batteries lie at the heart of most of today’s commercial electric vehicles. They are made from materials such as lithium, nickel, manganese and cobalt, which are expensive to mine and, in some cases, unsustainable. This is why the industry is determined to find the most efficient way to recycle battery cells.

“Our aim is to establish a sustainable value chain for lithium-ion batteries. Our technology can recycle almost all the materials used in cell production – not just for the batteries used in e-mobility, but also for the kinds of smaller batteries found in consumer electronics as well as large, industrial storage batteries regardless of their Lithium-Ion-based chemistries,” says Mike O’Kronley, CEO Battery Resourcers. Conventional recycling options are based on complex processes that mechanically crush the battery cells and chemically separate the mix of materials into individual purified constituent elements such as nickel, cobalt, manganese and lithium. The new method developed by Battery Resourcers eliminates much of this chemical processing by allowing the material mix to be turned into new active cathode material without the separation step, still resetting all memory from previous applications.

“This is a field that will be vitally important in the future. By investing in Battery Resourcers’ promising technology, we’re reinforcing our commitment to e-mobility,” says Kraft. As a key provider of high-tech manufacturing equipment, TRUMPF already plays an important role in driving forward e-mobility. The company’s systems and machines are ideally designed for tasks such as cutting sheet-metal components for battery housings and foils, and TRUMPF lasers are the perfect choice for welding battery cells, electronic contacts and electric motors.

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Electrification In The Automotive Industry

Electrification in the Automotive Industry

The automotive industry is on the brink of colossal changes. Marat Faingertz of ISCAR looks into the impact of this trend on the metalworking industry, and how new machining requirements can be addressed.

Public awareness of global warming, together with a pressing concern to create and maintain a clean environment, has led to a series of legislations worldwide that is forcing automakers to decrease CO2 emissions. Apart from improving fuel consumption, downsizing engines, and making lighter vehicles, automakers must turn to new technologies in order to cope with these emission limitations.

A rapid increase in battery electric vehicle (BEV) development, manufacture, and implementation, shows that electric vehicles are not only the future but are, in fact, the present. The automotive industry is on the brink of colossal changes and soon our perception of cars and transportation may alter completely.

ISCAR, a company with many years of experience in the production of metal cutting tools, offers unique, cutting-edge solutions for the new BEV Industry. As a leader in providing productive and cost-effective machining solutions, ISCAR strives to stay up to date with all the new trends and technologies and be a part of a brighter, greener future.

The following is a list of some of the common component machining processes in the BEV industry and some of the leading possible machining solutions and recommendations for each part.

Stator Housing Machining

One of the most notable trends of the electric vehicle powertrain is its simplicity. There are far fewer moving parts compared to the traditional internal combustion engine (ICE), therefore, manufacturing time and cost dramatically drop when producing BEVs. 

One of the main components of an electric motor is the motor (stator) housing made from aluminium. A special approach is needed to achieve this part’s critical key characteristics of lightweight, durability, ductility, surface finish and precision, including geometrical tolerances. The partially hollow form represents an additional challenge and maintaining low cutting forces is essential for roughness and cylindricity requirements.

ISCAR’s complete machining solution for this process has facilitated the transformation from the standard costly lathe-based process to an economical machining centre. Our aim is to reduce scrapped parts and reach an optimal CPK ratio (Process Capability Index—a producer’s capability to produce parts within the required tolerance).

Main Diameter Reaming

The most challenging operation in machining the aluminium stator housing is the main diameter boring and reaming. Because of the trend to use low power machines, the tool’s large diameter and long overhang require creative thinking to minimise weight and spindle load while maintaining rigidity. Exotic materials such as titanium and carbon fibre are used for the tool body, as well as the welded frame design.

The use of Finite Element Method (FEM) helps resolve the obstacles associated with this challenging application by enabling the consideration of many parameters, such as cutting forces, displacement field during machining, natural frequency, and maximum deformation.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Automotive Manufacturing Developments In Southeast Asia Amid COVID-19

SLM Solutions Signs MoU For The Purchase Of Five NXG XII 600 With Major European OEM

ANCA’s Third Tool Of The Year Competition Celebrates Modern Cutting Tools That Shape Our World

Toyota Strengthens Automotive Production Amidst Challenging Year

Toyota To Invest Two Billion In Indonesia For Electric Vehicles

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

VinBus Operates First Smart Electric Bus In Vietnam

VinBus Operates First Smart Electric Bus In Vietnam

VinBus Ecology Transport Services Limited Liability Company has opened and put into operation the first smart electric bus in Vietnam. The first electric bus lines will operate in Vinhomes Ocean Park (Gia Lam) and connect with the city’s public passenger transport system in the coming time.

VinBus is an electric bus model manufactured and assembled by VinFast at the Automobile Manufacture Complex in Hai Phong, combining many modern technologies with the smartest and safest features according to the strategy of current VinFasts smart electric bus series.

As smart electric buses, VinBus provides passengers with an outstanding comfort and safe experience. Buses are equipped with the automatic system that controls the drivers behaviour and warns unsafe dangers; automatic lowering mode of the bodywork suitable for the elderly, children, disabled persons, pregnant women; Electronic board announces the upcoming stop; Free WiFi, USB charging port, entertainment monitor and security camera system and itinerary control, turning back alarm, parking monitoring

VinBus owns a battery capacity of 281 kWh, capable of moving up to 220 – 260km. Buses are fully charged after only 2 hours at VinBuss 150kW fast charging station system with the worlds leading charging technology provided by StarCharge.

All buses of VinBus will be managed and operated intelligently through centralized monitoring, charging, safety inspection, maintenance, repair, and automatic cleaning at Depot stations scientifically arranged according to VinBus primary lines. The construction standard of the Depot stations is on a campus of more than 1 hectare, the roof equipped with solar panels, ensuring energy supply for Depot activities, contributing to reducing the pressure load of the power source for the national power system, environmental protection.

 

Check these articles out:

Thailand BOI Introduces EV Package And Over 35 Billion Baht In Investments

Operating in the Single-Digit Micron Range

Hypertherm Introduces Extreme Bevel Plasma Consumables For Its Air And Oxygen Plasma System

TRUMPF Unveils New New 3D printer To Help Fabricators Move Into Mass Production

Hexagon Launches Next Generation, Entry-Level Multisensor CMM

Fagor Arrasate Intelligent Stamping Systems Showcased At MetalForm China Fair

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Driving Hard On The Race Track: Wear-Resistant Iglidur Gears In The Gearbox

Driving Hard On The Race Track: Wear-Resistant iglidur Gears In The Gearbox

The iglidur I6 gears from the 3D printer for car racing of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) challenge

Electromobility is a crucial topic of the future. For Germany to be in the pole position, it is important to inspire young minds to take up scientific and engineering professions. Towards this purpose, the annual JET Challenge takes place at the IdeenExpo in Hanover. Students are given the task of building a fast, tough and energy-efficient racing car from a standard, remote-controlled car with a limited budget. Wear-resistant 3D-printed gears from igus made from the high-performance plastic iglidur I6 helped in this endeavour.

Build a fast, energy-saving racing car from an ordinary, remote-controlled car and overtake all other teams in a race – that’s the goal of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) Challenge, organised by the Society of German Engineers (Verein Deutscher Ingenieure – VDI) and the University of Hanover (Hochschule Hannover – HSH). As with the renowned models, the key factor is not speed alone, but also energy efficiency. In June 2019, visitors to the IdeenExpo can see the JET Challenge in action at the HSH trade fair stand. 25 teams compete for victory with their racing cars on a 1:10 scale on a 20-metre race track. The rules are strict. Available to each team is a budget of just 50 euros. Apart from battery, motor and speed controller, all components must be purchased, developed or built by yourself.

Save money with the igus 3D printing service

The teams are currently preparing for the next IdeenExpo. Students of the Eugen Reintjes vocational school are relying on a wear-resistant and tough gear transmission to enhance the performance of their race car. The biggest difficulty with this gearbox was the gear procurement. Due to the small budget, the students couldn’t afford big innovations. Finally, they found what they were looking for at the motion plastics specialist igus in Cologne: cost-effective, low-wear gears from the SLS printer. After a simple online configuration, the gears were printed and provided, made from the high-performance plastic iglidur I6.

High performance plastic makes race cars tough

Laboratory tests prove that the material I6 is significantly tougher than other plastics. In an experiment at our in-house test laboratory, the engineers tested gears made of polyoxymethylene (POM) and iglidur I6 at 12 revolutions per minute and loaded with 5Nm. A machined gear made of POM failed after 621,000 revolutions, while iglidur I6 was still in very good condition after one million revolutions. Thus, the team does not have to worry about potential failures. The gears in the racing car have already successfully completed an initial test run. The car is energy efficient and still reaches the top speed of 60km/h.

The young engineers support from igus promotes innovative projects

Innovative projects such as the race car gears for the JET Challenge are supported by igus as part of the young engineers support. The initiative supports young pupils, students and inventors in the development and execution of their technical projects. Further information on yes can be found at http://www.igus.sg/yes.

 

Check these articles out:

Automotive OEMs Must Improve Online Sales Models To Mitigate COVID-19 Sales Slump

Thailand To Establish Committee For Electric Vehicles

Thai Airways To Move Ahead With MRO Project Despite Airbus Dropout

Vinfast Opens R&D Center In Australia

A Company At The Heart Of The Car Industry

New Trends and Opportunities on the Road to Electromobility

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

3D Printing The Future Of E-Mobility Tools

3D Printing the Future of E-Mobility Tools

Kennametal’s 3D printed stator bore tool meets accuracy, roundness, and surface finish requirements of hybrid and electric vehicles.

Kennametal has developed a 3D printed stator bore tool specifically designed to meet growing customer demand for lighter weight tooling solutions used to machine components for hybrid and electric vehicles.

E-mobility components are typically machined on smaller, low horsepower CNC machining centres that require lighter weight tooling solutions. Kennametal’s 3D printed stator bore tool weighs half that of the conventionally manufactured version, while still meeting accuracy, roundness, and surface finish requirements for aluminium motor body boring.

“The main bore, which houses the stator of an electric motor measures approximately 250 mm in diameter (9.84 in) and approximately 400 mm (15.74 in) in length, with a smaller bearing bore at the bottom,” says Harald Bruetting, Manager, Program Engineering, at Kennametal. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kg (55 lb), far too heavy for the existing machine tool or for an operator working with the tool.”

Bruetting and Kennametal’s Solution Engineering Group turned to the company’s in-house additive manufacturing capabilities to 3D-print a strong but lightweight indexable tool, equipped with proven Kennametal technologies including fine adjustable RIQ reaming inserts for high precision finishing and a KM4X adaptor for maximum rigidity. The tool also features internal 3D printed cooling channels that help maximize productivity and tool life.

To continue reading this article, head on over to our Ebook!

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Hyundai Motor And Singtel Collaborate To Advance Singapore’s Smart Mobility Ecosystem And Industry 4.0 Journey

Hyundai Motor And Singtel Collaborate To Advance Singapore’s Smart Mobility Ecosystem And Industry 4.0 Journey

Hyundai Motor Company and Singtel has signed a Memorandum of Understanding (MOU) to collaborate on a range of ventures to support smart manufacturing, connectivity for electric vehicle battery subscription service. The MOU follows Hyundai Motor Group’s announcement in October 2020 that it is setting up a new state-of-the-art Hyundai Motor Group Innovation Centre Singapore (HMGICS) to conduct studies on future mobility and explore innovative solutions, services and disruptive technologies to revolutionise commuters’ transport experience.

Hyundai Motor will combine its expertise in developing innovative automotive and manufacturing solutions with Singtel’s capabilities in 5G, Internet of Things (IoT), and next generation info-communications technologies and solutions to develop Industry 4.0 advanced digital solutions to   transform the way vehicles are currently manufactured. The parties will develop and pilot a 5G-enabled smart factory use case for HMGICS’ intelligent manufacturing platform, and potentially scaling it up for deployment across Hyundai’s manufacturing plants globally.

“Hyundai is delighted to work with Singtel, implementing next-generation communication solutions that will enhance mobility experiences for our customers,” said Hong Bum Jung, Senior Vice President of HMGICS at Hyundai Motor Company. “We also hope to explore future innovative solutions and business opportunities with Singtel to help realise Singapore’s Smart Nation vision.”

Hyundai and Singtel will also work together on an IoT communications solution for the batteries powering Hyundai’s electric vehicles (EVs) in Singapore. The IoT system enables Hyundai to monitor the telemetry, or automatic data transmission, of the batteries’ real-time status and performance. The data-driven insights can enhance the EVs’ reliability, advancing Singapore’s EV ecosystem and Smart Nation vision of connected and sustainable mobility solutions.

Andrew Lim, Managing Director, Government and Large Enterprise, Group Enterprise at Singtel said, “Our collaboration with Hyundai Motor is timely given the Singapore Government’s decision to phase out internal combustion engine vehicles by 2040 and the recent Budget announcement on new policies to encourage more Singaporeans to switch to driving electric vehicles. By pushing the boundaries of what is possible with 5G, IoT and other advanced technologies, we also want to build up Singapore’s smart manufacturing and Industry 4.0 capabilities and strengthen its innovation ecosystem.”

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Germany’s First Electric Car Factory Sets New Standards

Germany’s First Electric Car Factory Sets New Standards

The world’s largest car manufacturer is getting ready for the future. Over the next few years, Volkswagen will make a radical transition to e-mobility, and the Volkswagen plant in Zwickau, Germany, will play a key role in this process. With the ID.3 model, the blueprint for the new generation of electric cars is being created here. And the bending experts from Bystronic are also on board. Article by Stefan Jermann, Bystronic.

Much of what happens in the automotive industry goes on behind closed doors. This includes the realignment of the manufacturers towards e-mobility. But when German Chancellor Angela Merkel herself fires the starting signal for the production of the new Volkswagen ID.3, everything is already very much in the open. This was the case in Zwickau, Germany, where the production lines for what could be the most ambitious current project in the entire automotive industry kicked into motion.

The ID.3 is more than just a new model; this new electric car embodies the future of Volkswagen and is intended to usher in a new era. The group has set itself the objective of becoming the leading global manufacturer of e-vehicles. And this mission is being pursued with a vengeance. With investments of €1.2 billion, Volkswagen wants to turn Zwickau into the home of Europe’s largest e-mobility factory. This year, more than 330,000 electric cars are scheduled to roll off the production line—a total of six models from the Volkswagen, Audi, and Seat brands.

Platform for the Whole Family

So far, sales of electric cars have been sluggish. The ID.3 is designed to change this—thanks to an attractive price of below €30,000, rapid charging capability, and a range of up to 550km. Jürgen Stackmann, a member of the Board of Management of the Volkswagen Passenger Cars brand, promises, “The size of a Golf on the outside, the space of a Passat on the inside, and the acceleration of a GTI.” 

The ID.3, the first model in the ID. family, forms the basis for a zero-emission generation of vehicles. The modular electric drive matrix—MEB for short—offers the necessary scalability from the compact car to the bus. By 2022, it will be incorporated in 27 models of four Group brands. The “ID.R Pikes Peak” prototype has already proven that the sky is the limit. On June 24, 2018, at the mountain race in the United States bearing the same name, the supercar with its 680-horsepower electric four-wheel drive made motor racing history and beat the previous record set by rally legend Sebastien Loeb by a large margin. This sports car will remain a racetrack dream, but it shows in an impressive way what the ID family can achieve.

76-second Cycle Time

Kati Langer stands in Production Hall No. 12. She is inspecting the Xpert 40, which is connected to two Kuka robots in a production cell. The passionate Bystronic saleswoman, who has accompanied the ID.3 project with Volkswagen from the outset, is proud of the system. In order to seamlessly integrate the bending systems into Volkswagen’s workflows, we had to overcome a number of structural challenges,” she explains while we watch the two bending robots at work. 

The first robot removes the part from the container station and deposits it on the centring system. The second robot picks it up, swiftly feeds it to the bending machine, and performs the first of two bending steps. Then it returns the part to the centring system and the first robot completes the remaining bending steps. Subsequently, a stationary system welds two ball nuts to the part. The gripper then picks up the part and places it on the conveyor belt. 

The entire process takes exactly 76 sec. Watching the robots perform their bending sequences is a genuine delight. If you hadn’t seen it with your own eyes, you would hardly believe how elegantly and nimbly the two robots work hand in hand—or rather, gripper in gripper. Subsequently, the bent part is installed in the support structure of the chassis where it stabilizes the undercarriage. A second fully-automatic bending cell manufactures a component that is installed at the front of the car chassis.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Bending in the Smartphone Era

Tornos To Hold Intelligent Manufacturing Conference

How 3D Printed Titanium Motor Nodes Became A Game-Changer In E-Bikes

Honda Shuts Automobile Production In Philippines

Shifting Gears: Addressing New Requirements In EV Manufacturing

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Operating In The Single-Digit Micron Range

Operating in the Single-Digit Micron Range

Peter Mösle of Blum-Novotest talks about the trends happening in the automotive manufacturing industry, and how the company has kept up with manufacturers’ new requirements.

Peter Mösle, Head of Sales of the Measuring Machines business division at Blum-Novotest, spoke about current challenges around post-process measuring technology and the structural changes in the automotive and supplier industry.

BLUM-NOVOTEST HAS BEEN MANUFACTURING POST-PROCESS MEASURING MACHINES FOR THE AUTOMOTIVE INDUSTRY SINCE 1983. HOW HAVE THE MARKET REQUIREMENTS CHANGED SINCE THEN?

Peter Mösle (PM): Our measuring machines are part of the production lines, so changes in the machining centres often impact our area of responsibility directly. In particular, the continuous reduction in cycle times, but also the ever-decreasing tolerances are challenges that we must solve. Where workshop drawings previously specified tenths or at most a few hundredths of a millimetre, today’s requirements are in the single-digit micron range. Another key aspect is repeatability, which means the ability to investigate the fifth or 5,000th workpiece in a reproducible manner. 

Ultimately, all these measured results must also be doc

umented with a link to the workpiece. Alongside these technical requirements, there is the need for high flexibility in terms of type diversity as well as a long and functionally reliable service life—all at the lowest possible purchase price. The advent of electric mobility means that the deck is being reshuffled.

HOW DOES ELECTRIC MOBILITY INFLUENCE THE REQUIREMENTS PLACED ON YOUR POST-PROCESS MEASURING MACHINES?

PM: Electric mobility generally results in a substantially lower number of parts. Whereas combustion engines can consist of 1,200 to 2,500 individual parts, electric drives frequently require roughly a mere 10 percent of this number.

Camshafts are a good example of this change. In recent years, they were developed from forged or turned components into what are called “assembled shafts”. With electric mobility, the shaft is retained as part of the rotor—without the cams but with other ultra-high-precision features that must be tested and evaluated. Even our most frequently delivered machines—brake disc measuring machines—must cater to changing requirements. As a consequence of the development of these components, we are confronted with innovative material combinations, coatings, or evaluation features, for which we have already delivered customer-specific solutions to expand our modular machine concepts.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Join Bruker Alicona Webinar: Form And Roughness Measurement With One System

The Importance of Automation for Networked Manufacturing and Digitisation

Modular Power Package For Demanding Benders

Hyundai Motor To Establish A Smart Mobility Innovation Centre In Singapore

Meeting the Need for Speed

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Laser Applications In The Production Of Li-Ion Battery Cells And Packs

Laser Applications in the Production of Li-Ion Battery Cells and Packs

The laser is at the center of many solutions when it comes to the global e-mobility trend. Here are a few examples of laser cutting applications in battery cell manufacturing and assembly. Article by Trumpf.

The worldwide mobility transition is in full swing. The demand for components for electric cars and alternative drives is rising continually. In particular, high-performance components directly involved in the production of batteries, electric motors and power electronics for electromobility are at the center. More and more companies, predominately automotive suppliers, are also demanding new manufacturing solutions and technologies for alternative drive concepts, including the fuel cell.

The laser is at the center of many solutions. It connects battery cells into modules or packs. It ensures tightness and crash safety when joining battery packs and trays. It scores highly thanks to its green wavelength when copper welding contact parts without spatter. And it provides high-tensile connections in e-drives, which withstand the highly dynamic requirements.

Manufacturing Battery Cells

Battery cell manufacturing is subdivided into electrode manufacturing and cell assembly. Electrode manufacturing requires a high variety of different process steps: mixing of the slurry, coating, drying, calendaring as well as shaping, folding and stacking of the coated electrode foil. Some of them required laser technology:

  • Micro structuring of the electrode surface with ultra-short pulse lasers, for example, reduces subsequently the charging time of battery cells.
  • Drying of electrodes with VCSEL laser technology to complement conventional drying ovens by reducing the footprint and increase efficiency.
  • Cutting and shaping of coated electrode foils with ns lasers into the required format, increasing quality and productivity. Common foil materials are aluminium (cathode) with a 5-14 µm thickness as well as copper (anode) with a thickness of 9-13 µm. Very often, these foils are coated. Cutting these foils with TruFiber laser sources enables burrs of less than 5 µm and HAZ of less than 40µm. 

In the cell assembly, the steps are contacting, packaging, formation, and aging. Laser technology is used here mainly in welding applications for the internal contacting of battery cell components and the closing of prismatic cell formats:

  • Green laser wavelength for the very defined and repeatable welding of copper materials.
  • High power IR lasers combined with Trumpf’s BrightLineWeld technology for spatter free welding of aluminium or copper materials.

Both laser applications enable the highest mechanical strength and lowest electrical resistance in welding of ≤100 foils together to a stack.

On the cell level, besides these different welding applications, there are also some upcoming laser applications for surface processing like cleaning, de-coating or micro structuring with short or ultra-short pulse lasers.

Process stability is a key factor in the battery cell production. Therefore, all these laser technologies have a direct impact on the efficiency and performance of the battery.

Battery Module Assembly

After the battery cell manufacturing process, the single cells will be assembled to a battery module. The electronics and battery pack assembly have an enormous variance of different module designs. But all are based on prismatic, pouch or cylindrical cell formats.

Laser technology is used in welding of busbars, meaning the electrical contacting of single cells to a battery module, or other current carrying components. Due to the enormous number of different designs, material combinations and thicknesses, the full TRUMPF laser portfolio in terms of power, wavelength, beam quality is applied.

  • Especially for thicker aluminium busbars with welding depths mostly >2 mm and welding speeds of minimum 100 mm per second, the TruDisk laser series with patented beam shaping technology BrightLineWeld is the best choice since every single weld must be exactly the same and spatter projections must be avoided.
  • For the welding of dissimilar material combination like Al/Cu or Al/steal, we mostly recommend single mode IR lasers with a very high beam quality e.g. you can use the TruFiber Series for such applications. These lasers create a very small intermetallic phase in the welding seam, which is important for a strong joint of materials with quite different melting temperatures. By using different welding patterns, you can join Al with Cu or even the other way around. Typically, by oscillating the laser beam with a scanner optic to increase the cross-section area. For the contacting of cylindrical cells, the sheet thicknesses are usually in the range 0.2 – 0.5mm, and many times dissimilar material combinations or with coatings.

For most of the installations in battery and module manufacturing, TRUMPF lasers, optics and sensors are integrated in automated high-volume production lines, while its TruLaser Station and TruLaser Cell series are suitable in small- and medium-production volumes.

 

Check these articles out:

Laser Technology Improves Post-Process Measuring On Centreless Grinders

Fibre Laser or CO2 Laser—Which Will Prevail?

TRUMPF Reports Higher Sales, But Decline In Orders Received

Thailand BOI Introduces EV Package And Over 35 Billion Baht In Investments

SPI Lasers Appoints New CEO

Are Machining Centres Taking Over Jig Bore Work?

igus 3D Printing Service: Quick Delivery Of Lubrication-Free Components

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

  • 1
  • 2
Back To Top