TWI helped to overcome hurdles associated with the fixturing and manufacture of high voltage modules, including structural welds in the module’s frame containing the cells and welding of the cell control system (CCS) to the individual cell terminals.
The work, which was to support BMW entering into module prototype production in the UK, has been supported with funding from the Advanced Propulsion Centre (APC). It included tooling design and manufacture, the development of laser welding procedure specifications (WPSs) for CCS to terminal and module frame joints, validation on live assemblies, series prototype production (involving both assembly and welding) and logistics (component receipt, storage, packaging and dispatch). Additional work was done in confirming incoming cell status and a number of in-line process checks and procedures to ensure finished quality.
Paola De Bono, TWI’s lasers section manager, said: “Our technical team of design, fabrication and welding experts has worked closely with BMW to find innovative solutions to the unique challenges associated with electric vehicle battery production."
BMW is an industrial member of TWI, which is planning to create a dedicated EV centre to assist with the growth of this important area of the automotive industry.
