Abstract
Every traditional and many emerging automotive OEMs have announced new electric powered production vehicles for sale in the next 24 months. While the powertrain architecture differs by OEM, the range, performance and cost of every electric vehicle is driven by the quality of the e-motor, battery pack and battery tray. This presentation will describe how coordinate measurement machines, sensors and software are being applied to improve the quality of these components in new electric vehicles.
First, the typical manufacturing process for electric motors for electric vehicles will be described. The process steps to shape the hairpins, build the stator assembly and shape the motor housing will be illustrated. The various types of coordinate measurement machines and where each can enhance quality will be shown.
Second, lithium-ion batteries are used in many battery packs to store energy for electric vehicles. A typical battery pack assembly process will be illustrated. Application of coordinate measuring machines at various process steps, to advance the quality of the battery pack, will be illustrated.
Third, battery trays hold hundreds of individual battery packs in a weather-resistant assembly that is often a part of the electric vehicle frame. Trays have a specific manufacturing process, designed to maximize mechanical strength and heat dissipation properties. Battery tray production methods will be presented, along with the pivotal points where coordinate measuring machines increase the level of quality.
Design, Quality and Manufacturing engineers will benefit by learning how their product quality can be improved. No prerequisite knowledge of coordinate measurement machines, electric vehicle powertrain architecture or quality measurement solutions is required.
Cite this paper
David Wick. ZEISS Industrial Quality Solutions, Maple Grove, MN. Presented at the Coordinate Metrology Systems Conference 2020, virtual conference, September 2020. Coordinate Metrology Society, reference CMS-2020-006.