The automotive industry is increasingly relying on electric drives, The consequences
for production are enormous: the components needed for vehicles with a combustion
engine are changing or are no longer necessary, while others are being added –
battery trays, for example. Totally new production processes are therefore required,
including in welding technology.
Battery trays are used in electrically driven vehicles to protect the battety against
outside influences. Much is demanded of the components: they must be
compact, completely secure to protect the battery packs against corrosion, and
be extremely durable in the event of a collision. Extruding press and sand-cast
profiles are manufactured from aluminium alloys with wall thicknesses of
between two and six millimetres.
Only a few welding processes are suitable for joining this material in a stable,
efficient, and watertight manner. These include the process variants CMT (Cold
Metal Transfer), LSC (Low Spatter Control), and PMC (Pulse Multi Control). The
LaserHybrid welding process has advantages for long seams. The combination of
a laser and a conventional MIG welding process makes it possible to minimize
component distortion. The laser also ensures high welding speeds and therefore
short cycle times, deep penetration, and low heat input.
Fronius has already implemented a mechanized welding system for producing
battery trays for customers from the automobile supplier industry. The welding
process runs in an enclosed robot cell. An employee prepares the 1.6 x 2.2-
meter trays on clamping devices in a separate safety zone. This allows the
aluminium profile segments to be welded at high speed and in repeatable
quality. The cleanliness of the components and the close tolerances guarantee a
perfect weld seam — also reducing the amount of post-processing required. The
use of a mechanized welding system therefore reduces manufacturing costs and
improves levels of quality and efficiency in production.
For images, please check this page – https://www.fronius.com/en/welding-
technology/info-centre/magazine/2019/welding-battery-trays
