Application of Ultrasonic Welding Technology in EV Manufacturing
This article introduces the application of ultrasonic technology in electric vehicle manufacturing. Ultrasonic technology’s high efficiency, highly reliable connections, and environmentally friendly features boost the development of electric vehicles.
The growing demand for electric vehicles (EVs) has brought new challenges to the automotive industry in many areas, including lightweight body structures, manufacturing of electrical and electronic components, and battery manufacturing. If car manufacturers are to guarantee the highest quality levels and achieve the safety and environmental certifications associated with electric vehicles, innovative and economical production solutions are needed.
The ultrasonic welding process is used and recognized by everyone because of its high efficiency, highly reliable connection, and environmental friendliness. These characteristics are also in line with the requirements for electric vehicle production. Therefore, ultrasonic technology is an ideal process to solve many problems related to vehicle production.
1. Reliable connection of high-voltage cables for EVs
The motor used in electric vehicles must be able to provide full power output at the moment of starting. This requires a reliable connection of high-voltage cables in the car. Cables and plugs connecting charging stations to high-voltage batteries require reliable, low-contact resistance connections to enable fast charging. This usually requires effective welding of copper, aluminum, or a combination of the two to achieve the vehicle’s high-voltage cable connections.
Cables with cross-sections of 70, 95 or 120 mm² must be firmly welded to the high-current connecting lug. Design engineers require the welding width to be as narrow as possible to save installation space. While it is difficult to achieve using traditional processes, it is now easy to achieve reliable connections using ultrasonic welding.
2. Ultrasonic Welding of Tabs for Soft-pack Batteries
Welding of copper foil and aluminum foil tabs of soft pack batteries is also a typical ultrasonic welding application.
3. Ultrasonic Welding for Power Electronic Device
An IGBT is a type of device that can switch current quickly with minimal losses and is a key electronic component in power converters used in electrical drives and battery charging systems. The ultrasonic welding process is commonly used to produce IGBT power semiconductors.
4. Wire Harness Welding for Electrical Connections
Ultrasonic wire harness welding has obvious economic and technical advantages: simple process, high cost-effectiveness; low contact resistance; high connection strength, etc. The welding components are very flexible and easy to integrate into automated production lines. Even very thin cables with a cross-section of only 0.13mm2 and multi-strand cables used for high-speed data transmission can be welded using ultrasonic welding technology.
Automakers are not only striving to make the vehicles they produce more efficient, but they are also striving to leverage these technologies for greater efficiency and control. Therefore, electric vehicles and ultrasound technology reinforce each other and will continue to be closely linked in the future.
