Feature: Power
Securing consistent power for EVs By the technical team at TLM Laser
structuring some of their manufacturing processes. Although fewer traditional mechanical components are required
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within the vehicle’s drive train, this is off set by a signifi cant increase in the demand for cables, harnesses, connectors, busbars and, of course, the battery packs needed to deliver power. A key process in the production and assembly of EV battery packs is welding, and this is where the power, precision and fl exibility of the laser ensures safe, consistent and reliable connectivity.
30 February 2024
www.electronicsworld.co.uk
s the transition away from internal combustion engines to electrically-powered vehicles (EVs) and hybrids continues to gather pace, manufacturers are not only supporting the market by designing and building new models, they are also completely rethinking and re-
As the transition to EVs gathers pace, manufacturers are completely rethinking and re-structuring some of their manufacturing processes, too
Lightweight materials Battery packs for EVs are made of many individual battery cells joined together. Producing their connections presents several challenges for manufacturers, including the combination of different thin, highly-conductive materials of varying thicknesses that must be joined, whilst avoiding damage to the assembly as a result of any thermal or mechanical shock. A further challenge for EV manufacturers is the
power packs’ overall weight. Lightweight materials and composites can reduce the car’s weight, so there is increased use of lightweight aluminium in the current- conducting elements within EVs, such as the cables and busbars. In the past, the use of aluminium had been somewhat restricted due to difficulty in welding with conventional joining techniques. However, recent advances in laser welding have removed this obstacle, now allowing wider use of aluminium in both current-conducting and structural components. Laser welding delivers precise, measured and localised heat input, and the advanced process control and resultant consistency of the process makes it possible to achieve 100% good welds.
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