Innovative process solutions for electric vehicle manufacturing

Discover NEVs production challenges and reduce the risk in your electric vehicle manufacturing process (Adaptors, battery assembly, process control...).

The rapid transition towards e-mobility is stimulating demand for innovative solutions that support critical tasks on dedicated and mixed assembly lines during the electric vehicle manufacturing process. Stakeholders are more receptive to new production approaches and are prepared to make a significant investment in order to optimize production during ramp-up and guarantee higher quality and safety with increased traceability. This article discusses the risks and opportunities and provides you with experts’ solutions and suggestions.

Reducing risk and optimizing production in the electric vehicle manufacturing process

NEV production challenges  Assembly solutions  The road ahead

Consumer demand for electric vehicles is growing rapidly, driven by increasing awareness of climate change and the rising cost of fossil fuels. Consequently, the development of New Energy Vehicles (NEVs) is a key focus for the automotive industry.

At the UN Climate Change Conference (COP26), the automotive sector pledged to cease production of internal combustion engine vehicles globally by 2035. To meet this target, the development and production of affordable hybrid and fully electric vehicles must accelerate rapidly.

Production at scale of NEVs presents new challenges. For example, there are risks associated with battery-powered vehicles which require new skills to overcome. These include exposure to high voltage currents, as well as the risk of short circuits and overheating or fire if the battery is not fitted correctly. 

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New assembly processes are therefore required to deliver at scale while keeping workers safe and guaranteeing the quality of the finished product. These new solutions will provide: 

1. New tightening applications in different environments. 
2. Higher levels of automation and requirements on traceability. 
3. Flexibility to maximize production per line. 
4. Productivity to maximize the output per line, as the demand is high and further investments expensive. 
5. Last, and most importantly, higher safety standards for operators during the assembly of components with high-voltage contact. 

1. NEV production challenges

NEVs are powered in whole, or in part, by an electric motor that relies on a comparatively large battery, operating at several hundred volts due to the required power capacity. Battery packs consist of several hundred cells. Each cell is delivered with a minimum state of charge representing a voltage of at least 3.7 V. As a result, workers may come into contact with live parts and dangerous voltages. An electrical accident can be life-threatening depending on the voltage, current intensity and duration of exposure. Even a minor electrical shock can cause harm, such as uncontrolled muscle spasm, which can ultimately result in a serious accident.

Electric arc is another potential risk. If the distance between two electrical potentials is too great, the voltage can flash over unintentionally, sometimes generating temperatures of several thousand degrees Celsius, which can lead to serious burns. Loose contacts in components that have not been mounted correctly are a common source of arcing. Correct assembly is therefore critical in minimizing risk.

 And it is not only workers who may suffer the consequence of mistakes made during electric vehicle assembly. Assembly errors can also lead to failures later, which could endanger occupants, other road users, or pedestrians. Welding, flow punching and gluing are just as important to get right as tightening in this regard. So, not only must the required parameters such as torque and angle of rotation be safely maintained, but safe assembly must also be fully documented and traceable.

2. Assembly solutions

Assembly experts, such as Desoutter’s, have developed a wide range of corded and wifi-enabled assembly solutions designed to ensure that NEV assembly is safe, efficient, flexible and traceable. Several ranges of transducer-based tightening tools, for example, are equipped with torque and angle sensors to ensure that the joint is tightened using the correct tightening parameters.

Such tools feature insulating adaptors and can be equipped with guards to minimize the risk of dangerous contact voltages, making them ideal for power busbar connection. These products for worker protection have been tested and approved by Dekra according to IEC 60900:2018, IEC 60664-1 and EN 60745-1.

Sequenced tightening for total quality control can be achieved using worker assistance platforms:

Process control software, which guides the operator through each stage of the tightening process. One NEV application is securing the battery pack cover, which requires synchronous bolting to make sure the seal between the cover and lower casing is watertight.

Worker guidance systems that use a combination of lazer guidance and motion capture technology are being introduced to support Poka Yoke principles and deliver error-free tightening processes. Such systems eliminate operator error completely, ensuring that no bolt is overlooked and that the correct torque is applied every time. 

Multi-spindle solutions,allow synchronous assembly to the defined torque: for example, ensuring that modules in battery packs are mounted with adequate clamping force to eliminate settling, so that assembled components do not warp. Multi-spindle solutions improve cycle times significantly, particularly when used in conjunction with an automated bolt feeder. 

The exchange of tightening data with the higher-level control system can be assured using a smart hub in combination with wireless tools. For example, when a control system transmits the correct parameters for the upcoming tightening job to the tool, it receives the tightening results for traceability and documentation in return. 

Performance, quality and other NEV assembly parameters can be monitored constantly using data analysis dashboards. There is also the option to send real-time alerts to smartphones. Detailed data analytics with real-time KPIs for performance, quality and availability swift identification of production trends for continuous efficiency improvement. 

Big data analytics can also support total traceability. In the past, traceability data was stored separately and was not easy to interrogate. New big data solutions can collate and analyse data at every level of production and from any device or system, regardless of manufacturer. Automated reporting enables manufacturers and suppliers to access complex data sets at any time to obtain insights on virtually any aspect of quality and production, including: 

• % nok parts / station 
• average time per part / station 
• % assembly errors / station 
• process control alerts 
• empty tool’s battery alerts 
• missing parts alerts

These invaluable insights not only identify areas for continuously improving production efficiency and reducing cost, but also greatly reduce the likelihood of expensive and damaging product recalls.

3.  The road ahead

At Desoutter, we are committed to being part of the solution for a better tomorrow. Sustainability will continue to be a key driver for the automotive industry, and we are committed to developing flexible automation solutions for electric vehicle assembly that support zero defect working and advanced process control, together with high levels of worker safety and total traceability.