Unlocking creative potential for electric vehicle battery (EVB) assembly

Optimising the design of electric vehicle battery (EVB) assemblies is crucial to unlock new creative potential for electric vehicle design and efficiency of production. Here we look at how advanced fastening solutions from EJOT enable automotive engineers to achieve this.

As a global leader in the design and manufacture of fastening systems for the automotive industry for over 50 years, EJOT is ideally positioned to provide expert insights and products to help automotive designers to achieve the optimum fastener solution for EVB projects.

The experience and knowledge gained through working with major vehicle manufacturers throughout the world gives EJOT a unique perspective to help EV designers achieve the performance they seek. And, importantly, a clear understanding of the challenges as Steve Wynn, UK Sales Manager for Industrial Fastening Solutions at EJOT UK explained.

“We understand the challenges involved with ensuring the battery is as lightweight as possible to optimiseperformance and reduce energy consumption, while at the same time being designed for both water and air tightness and remaining fully serviceable,” said Steve.

“We also know that the EVB design must utilise a mix of connected components that are conductive in some instances, while requiring isolating qualities for safety reasons in other areas. And there is the critical issue of fastener cleanliness too, given that any contamination present within the electric powertrain can lead to short-circuiting.”

Fastening solutions for using lightweight materials in EV batteries

EJOT offers a range of advanced fastening systems for EVB assemblies which give designers solutions they can depend on to meet these goals and more, particularly in relation to using lightweight materials. It is a range built on decades of fastener innovation, including screws which helped pioneer the use of lightweight and thin sheet materials in the automotive industry in the 1970s, and today the latest versions of these products and systems are helping EV manufacturers benefit further.

For the EVB assembly, EJOT fasteners are enabling designers to shift away from using standard steel in motor housings to materials like aluminium and plastics, because they provide solutions capable of handling the different temperature and tolerance demands. And one of the fasteners at the forefront of EVB assembly is the ALtracs Plus thread forming screw for aluminium.

ALtracs Plus is a self-tapping screw which is helping to satisfy the increasing volume in this growth market area because of its suitability for lightweight construction. This results from its optimised thread geometry that facilitates the use of smaller and shorter screws, but still offering consistently high strength values.

These design characteristics and the high quality of the product make ALtracs Plus an ideal choice, but it is not the only EJOT fastener finding new purpose in this area of application. Another is the EVO PT, a high load capacity screw for direct fastening into plastics, which can also provide greater reliability of installation equipment. As is common with many EJOT fasteners, the EVO PT also offers the scope to reduce the number of parts needed in an EVB assembly, in turn meaning simpler installation.

Ticking all the boxes for EV designers

EJOT can help EVB designers arrive at a design that ticks all the boxes and ensure high levels of productivity can be maintained in the factory for Takt times to be met more reliably.

Steve added: “Finding new ways to apply our fasteners and provide high strength joints in plastics, composite materials, thin sheet metals and foams will be increasingly important as EV adoption and use grows. The continuous pursuit of improvements in the whole vehicle design, and particularly EVBs, is going to be key for the industry to deliver vehicles that are popular with drivers and suit their requirements without compromise, and we are delighted to be supporting that process.

“So if you are working on an EVB project, talk to us to explore how our range, including metal screws for plastics, plastic screws, friction-weld systems, plastic fasteners and removable fasteners, can help you achieve your design goals.”

Whilst the EVB is a key focus for EJOT, its fastening systems support designers in all areas of vehicle manufacturing. Its range can provide a solution across numerous automotive applications with consistent quality and performance assured – in ICE, hybrid and EV powered vehicles – including screws for use in body in white (BIW), e-connectivity, motors, lighting, seating and doors.

These products are backed up by EJOT’s valuable design tools which support designers as they integrate fasteners into new assembly designs. Amongst the resources available from EJOT is access to its specialist calculation software which can assist in the development process and potentially deliver savings in terms of time and costs.

Find out more at www.ejot.co.uk.