Battery Pack Case
Based on a variety of welding/joining solutions, ZEV manufactures battery pack cases tailored to customer requirements. We provide the best solutions throughout the entire process, from design/analysis to assembly and inspection based on our expert knowledge and know-how regarding BPC production
EV Exclusive Battery Pack Case
| Classification | FSW | MIG | LASER |
|---|---|---|---|
| Photo | FWS Tool Development Completed | ||
| Bead Width | 12mm | 8mm | 4mm |
| Welding Status | Good | Good | Good |
Design/Analysis
| Part design and forming analysis for components applying the press method. | ||
| Part design and forming analysis for components applying the extrusion method. | ||
| Flow and cooling analysis for the cooling plate |
LASER + FSW(BPC)
| Part Name | Material | Shaping | Welding |
|---|---|---|---|
| FRAME | A6N01S, 3.0T | Extrusion | LASER |
| COOLING UPR | A3003MOD H0, 1.5T | Press | BRAZING |
| COOLING LWR | A3003MOD H0, 1.5T | Press | |
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MIG + LASER(BPC)
| Part Name | Material | Shaping | Welding |
|---|---|---|---|
| FRAME | A6N01S, 3.0T | Extrusion | MIG(CMT) |
| COOLING UPR | A3003MOD H0, 1.5T | Press | LASER |
| COOLING LWR | A3003MOD H0, 1.5T | Press | |
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Quality Inspection
| ROBT FSW |
MAKER : ABB / ESAB - Purpose: Robot for friction stir welding- Features : Suitable for metal-to-metal and dissimilar material joints (including similar material joints) Welding with flush and overlapping possible No additional filler metal required → Environmentally friendly process |
FRICTION SPOT WELDING |
MAKER : HARMS WENDE - Purpose: Robot for friction stir welding- Features : END HOLE No post-process required (including similar material joints) Suitable for metal-to-metal and dissimilar material joints - No additional filler metal required → Environmentally friendly process |
| LASER WIRE WELDING |
MAKER : IPG - Purpose : Robot for low-heat laser welding- Features : Easy welding of sheet materials Minimal heat distortion due to low heat input Welding with flush and overlapping possible Welding possible in the case of gaps between base metals (compared to models without wire) Reduction of cracks due to wire application |
LASER SEAM STEPPER |
MAKER : IPG - Purpose: Linear laser welding equipment- Features : Safety rating Class 4 (Laser shielding → Safety booth not required) Two-way pressure possible (increases weldability in the case of gaps between base metals) → Minimum required flange area (around 20mm) |
| FDS |
MAKER : DEPRAG - Purpose: Robot for fastener assembly- Features : Pre-hole misalignment allowed up to 4 sheets can be overlapped Steel-to-aluminum dissimilar material joints possible Joining of non-metallic materials possible |
CMT (MIG / MAG) |
MAKER : FRONIUS - Purpose: Equipment for arc welding- Features : Large versatility for material application Weldability selection based on wire type Welding possible in the case of gaps between base metals (easy securing of a wide bead width) Economical compared to the initial investment cost |
| LASER WIRE WELDING(manual type) |
MAKER : JASIC - Purpose: Manual low-heat laser welding (Manual)- Features : Easy welding of sheet materials Minimal heat distortion due to low heat input Welding with flush and overlapping possible Welding possible in the case of gaps between base metals (compared to models without wire) Reduction of cracks due to wire application |
RSW |
MAKER : HARMS WENDE - Purpose: Equipment for electric resistance spot welding- Features : Fast overlapping welding speed Convenient maintenance Economical compared to the initial investment cost Large versatility for material application |
Process configuration
| Division | Product Name | Molding method | Welding/Joining | Note | |
|---|---|---|---|---|---|
| 1st process | Frame Outside | Extrusion | MIG | Main Jig 1 (front) | |
| 2nd process | Inside the Frame | ||||
| 3rd process | Frame Rear | ||||
| 4th process | FRAME + COOLING | Extrusion/press | Main Jig 1 (front) | ||
| 5th process | FSW | Main Jig 1 (rear) | |||
| 6th process | Small parts (PIPE, BRKT) | Extrusion/press | MIG | Main Jig 1 | |
| 7th process | UNDER COVER | Press | FDS | Main Jig 3 | |
| 8th process | UPR COVER | BOLT | - | ||