More drivers are transitioning to electric vehicles (EVs) year-on-year, as shown in the latest market analysis. In 2022, nearly 1 in 6 vehicles sold used electric drives and currently, the market is on track to account for 18% of total vehicle sales in 2023, according to research from the International Energy Association (IEA).
Advanced screwdriving systems play a vital role in ensuring part-to-part repeatability during the EV assembly process. In EV component manufacturing, the safety factors for each fastener may require tighter tolerances and demonstrable proof of compliance with more demanding technical specifications. In this blog, we’ll look at why EV component assemblies require stringent validation procedures in fastening and screwdriving applications, and how an automated solution can assist with improving both the reliability of the assembly and ensure greater operator safety.
The automation journey became a necessity due to the stringent safety requirements needed to protect operators, ensure manufacturing reliability, and deliver a cost-effective production process that also reduces scrap rates by a significant percentage. During the initial development of EVs, there were many bottlenecks, quality concerns, and limited throughput in their assembly operations. By moving to automated assembly for crucial parts such as battery packs, chassis, and electrical drives, the company was able to drastically ramp up production of economically priced models every year and keep up with their rising consumer demand.
Some of the major hazardous operations in EV assembly operations include:
Regulations struggled to keep up with major developments but as failure rates increased, a certain duty of care fell on the manufacturers of these critical components. Because of this self-regulation, ensuring product quality became non-negotiable.
Steps taken during the pre-assembly preparation, sub-component assembly, the connection of battery-pack modules, and vehicle integration works that include wiring electrical components are becoming ever more complex. Maximizing output may require a screwdriving solution with an integrated feed system that can automatically stage, feed, and drive fasteners at less than a second per cycle.
To error-proof your EV assembly line’s screwdriving operations, you’ll need:
These advanced capabilities allow manufacturers of crucial electromechanical devices to error-proof their assembly lines and ensure zero failures while providing in-process quality validation during their screwdriving and fastening operations. WEBER’s advanced handheld and automated screwdriving systems, along with the auxiliary traceability solutions enable high-speed, accurate, and consistent operations when aiming for a profitable, but also safe and efficient assembly method for EV components.
At WEBER, we work with manufacturers of EV components and parts to develop a fit-for-purpose screwdriving system. Our process controllers can measure the torque, angle, and depth of the screwdriving operation, providing you with accurate feedback that you’ve achieved your target clamp load every time. With quick-change tooling, configurable stroke lengths, vacuum technology for harder-to-reach applications, and process control that integrates with your Manufacturing Execution System (MES), you can deploy the most advanced screwdriving system that delivers the throughput you need.
Our team is ready to tackle your unique EV component assembly challenges. Reach out to discuss your application today.