What happens after a battery module is assembled?

After the battery module is assembled, it needs to be placed into the battery tray. As this tray is a key structural component of the vehicle as well as integral in protecting the battery cells, it needs to be of the highest strength and stability.

How can automated disassembly be introduced in the future?

Once the production of batteries has increased, automated disassembly can be introduced in the future. For this to be possible, it is important to consider the design of the battery and to make sure it has a minimized amount of materials and parts, in addition to suitable joining techniques.

How a battery design is developed?

The design solutions are assessed from an assembly, disassembly and modularity point of view to establish what solutions are of interest. Based on the evaluation, an “ideal” battery is developed with focus on the hardware, hence the housing, attachment of modules and wires, thermal system and battery management box.

How does a battery tray assembly work?

The battery tray assembly consists of several production steps. Depending on the battery design and manufacturing processes, manual tightening with bolt positioning and process control, or flow drill fastening with K-Flow technology can bring the needed process quality, productivity and flexibility.

How are battery housings assembled?

All battery housings are assembled using screws which is beneficial for the disassembly since it is possible to remove the lid without damaging it. However, a large amount of screws is needed, making it a time-consuming activity and an increased number of parts results in longer lead times as well as higher material usage.

What are some examples of module assembly & disassembly?

Another good example of module assembly and disassembly is found in Tesla S which also has modules mounted to the pack with four screws. To access these screws a plastic cover must be removed, but once that is gone, it is easy to unscrew the modules and later on lift them.