Abstract
Ensuring the precision and repeatability of component assembly in the production of electric vehicle (EV) battery modules requires fast and accurate measuring methods. The durability of EV battery packs depends on the quality of welded connections, therefore exact positioning of the module components is critical for ensuring safety in exploitation. Laser welding is a non-contact process capable of welding dissimilar materials with high precision, for that reason it has become the preferred joining method in battery production. In high volume manufacturing, one of the main production challenges is reducing the time required for assessment of dimensional and geometrical accuracy prior to joining. This paper reviews the challenges of EV battery design and manufacturing and discusses commercially available scanner-based measurement systems suitable for fabrication of battery pack components. Versatility of novel metrological systems creates new opportunities for increasing the production speed, quality and safety of EV battery modules.
Highlights
Modern electrified vehicles (EV), both full and hybrid models, are gaining popularity because of market pull and technology push for e-mobility
Speed of a battery pack is influenced by the precision of the chosen measurement and welding methods
The throughput rate is limited by the design of the busbars or other connector elements
Summary
Modern electrified vehicles (EV), both full and hybrid models, are gaining popularity because of market pull and technology push for e-mobility. The main efforts in the popularization of electric drivetrain technology have been concentrated on developing batteries with higher energy density and expansion of charging infrastructure [1]. Present day electric vehicles are powered by battery packs using lithium-ion technology, which are widely used in consumer electronics. Innovations in battery cell technology have made electrically powered cars affordable for personal use, whereas applications for long distant transport are restricted because of the power of batteries and the availability of the fast charging points being limited. Governmental authorities have been tightening emission regulations to decrease the environmental impact of transportation through the wider use of renewable energy sources. Global governmental strategies and policies to support the efforts of the automotive industry
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