Employing controlled tightening for optimum results
Employing fully optimised and monitored tightening strategies throughout EV assembly is a key consideration for vehicle manufacturers seeking to ensure the correct clamping force is applied to joints without compromising on quality or hindering cycle times. In addition, the extensive use of a range of lightweight materials in EV construction presents a further challenge in terms of ensuring joint integrity between materials with varying properties that behave differently when clamping force is applied.
March 21, 2024
With battery modules forming a central part of the vehicle bodyshell, joint integrity in the battery assembly process is a specific area of focus due to the need for the module to maintain its structural integrity in the event of a collision. Once constructed, battery modules need to be mounted on top of a liquid gap filler paste in the battery tray. Although this can be achieved with tightening, the soft joint behaviour of the gap filler presents a challenge in production, due to the tendency of gap filler adhesive to squeeze out between the module and tray. This can lead to air remaining trapped within the battery module, compromising thermal transfer.
A fully controllable tightening strategy is required to achieve optimum results and guarantee even distribution and full contact between the battery modules and the gap filler. Atlas Copco’s industry-leading nutrunners provide a multi-spindle solution, which deliver a simultaneous tightening process.
This process is electronically controlled by Atlas Copco’s space saving PF6 Flex System platform, in order to ensure a consistent tightening process, quality assurance and traceability via data collection and visualisation. By working synchronously in the final tightening process, the assembly cycle time is reduced and each module is fixed evenly in the tray. Optimum contact is achieved by employing a programmed tightening strategy with a precise tightening sequence, that accounts for the behaviour of the liquid conducting paste.
Atlas Copco also enables manufacturers to protect operators from the risk of exposure to high voltages in battery assembly through a range of galvanically-insulated components for handheld electric assembly tools. Products include fully insulated sockets and quick change adapters, as well as insulated tool covers.
As a world-leading provider of innovative joining technologies for the automotive industry, Atlas Copco’s tightening strategies for module mounting enables precise application of the battery modules to the tray, whilst maintaining short cycle times, process reliability and operator safety.
With innovative joining technologies and a range of solutions that can be applied throughout the entire EV assembly process, Atlas Copco is your strategic partner for electromobility. Take a look at our video to see how we can help with your electromobility needs.