Driving the future of Electric Vehicle Battery production

Each year brings new electric vehicle models to market from both well-established manufacturers and new brands. 

The whole industry around electrification is changing at high speed, especially when it comes to the heart of the electric vehicle – the battery. The required driving range and the challenge to minimize charging time increases continuously.

Different types of battery cells, such as as cylindric cells, prismatic cells, or pouch cells, influence the production process.

Battery weight needs to be reduced significantly and production processes need to be optimized and globally scalable. In addition, the overall design is constantly adapting due to changes in products and available resources.

0-1. Cell component and cell inspection
Using inspection systems to monitor product quality for all types of battery cells and battery components early in the process ensures resource and cost efficiency in production. They supply system operators with information on the process and product quality and highlight the potential for optimization.

2. Cell stack assembly
Different production methods for cylindric cells and prismatic ones are needed. A perfect combination of dispensing systems for the cell bonding and self-pierce riveting systems for assembling the modules increases quality, for instance, the bonding of the cells using a two component (2C) material. For cylindric cells, low viscosity material by multi-dot injection and bonding of the side walls is the optimal choice.

3. Module assembly
After stacking cells together, they need a solid framing around to build a module.

4. Battery tray assembly
The assembled battery module needs to be placed correctly into the battery tray. A high-quality tray is essential to ensure the battery can provide optimal performance also giving structural stability to the whole car.

5. Thermal management
A thermal compound material is needed to manage the battery heat. A detailed check of the tray and correct material calculation provides the right foundation for the optimal application of gap filler with a dispensing system.

Batteries require new innovations like insulated sockets to protect operators from high voltages and prevent short circuits or grounding that could cause serious injury.

Ensuring the battery tray is sealed properly before the cover is mounted is a crucial part of the battery assembly. Precision solutions that do not introduce heat or use certain materials are required to achieve proper isolation of the internal and external atmospheres.