Latest OnDemand BEV TECHTALKS 2023

• Manufacturers are commonly faced with challenges related to labor availability, increasing costs and inflation, and improving quality – leveraging automation addresses many of these problems.

• Bonding automation offers numerous benefits, including improved process efficiency, reduced defects, the ability to explore new solutions, and significant cost savings. By streamlining tape and adhesive dispensing and application, automation enhances productivity, precision, and overall operational effectiveness.

• Partner with 3M to overcome your most critical bonding challenges, including tape and adhesive selection, design and simulation, and production automation.

• VHB™ Extrudable Tape is an innovative new solution that combines many of the benefits of a tape, with the automation capabilities traditionally limited to liquid adhesives.

• The RoboTape™ System for 3M™ Tape is an advanced solution that automates the application of 3M™ Tape in a process that was traditionally done manually.

• The 3M Bonding Process Center can help you see what is possible for automating your bonding application.  Collaborate with 3M’s team of tape and adhesive automation experts to design a process that fits your application needs.

• The 3M Bonding Automation Network is a collection of system integrators, dispensing companies and robotics experts that 3M will connect customers with to implement solutions.

Electric vehicle development to replace a mature ICE counterpart requires out-of-the-box thinking. The adoption of simulation-driven methodology is not only vital to the optimal usage of human resources and materials, but also the most viable solution to innovation. The consolidation of vehicle platforms by vehicle manufacturers demands a modular approach for electric motor design, which in itself lends to shared technology across vehicle platforms and manufacturers.

In this webinar, we present the value of using a unified modeling and simulation process that leverages the CAD-CAE connectivity for developing a new electric drive system or re-using one from an existing vehicle program. With the creation of a modular, fully-parametric and simulation-friendly electric drive model, it is possible to explore untouched design possibilities and test all possible scenarios in a more affordable time frame—thereby, accelerating the vehicle development program and preventing valuable engineering resources from being wasted.

• Identify and compare key dielectric solutions for electrical insulation of battery components

• Advantages and Disadvantages in manufacturing process

• Comparison of Electrical insulation performance

• Comparison of Edge coverage performance

• Comparison of Adhesion and durability performance

The development of vehicles powered by battery or hydrogen requires out-of-the-box thinking. The adoption of simulation-driven methodology is not only vital to the optimal usage of human resources and materials, but also the most viable solution to innovation. The consolidation of vehicle platforms by vehicle manufacturers demands a modular approach for electric motor and battery pack design, which in itself lends to shared technology across vehicle platforms and manufacturers.

While significant resources are allocated to develop new battery technologies, vehicle manufacturers are looking into alternative fuel sources such as hydrogen due to stringent timelines to eliminate the sales of internal combustion engine (ICE) based vehicles. Fuel cell electric vehicles (FCEVs) operating with green hydrogen technology are a promising alternative to battery electric vehicles (BEVs). Fuel cells are more suitable for large vehicles such as trucks and trains considering the challenging battery size requirements for such large vehicles. In addition, they require less expensive commodities while tending towards zero emission, zero waste and no grid impact.

In this webinar, we will share a simulation driven methodology that can be adopted at any stage of propulsion system development for both BEVs and FCEVs with a robust, industry validated connected process. This includes leveraging pre-packaged workflows that apply to electric vehicles such as inverters and electric drives, as well as to bipolar plates and gas diffusion layers in hydrogen fuel cells. This highly scalable, customizable process will empower propulsion system engineering teams to develop solutions that are both suitable for the vehicle platform and exceed industry requirements.

The session addresses a simple joining of materials with the highest conductivity joint – keeping electrical resistance (and heat generated) to a minimum – reducing heat, reducing cooling systems energy consumption- in tern contributing to increasing vehicle range.

• Connecting aluminum, copper and other metals to connect leads and cells together

• How to connect different elements of the battery: E Clinching overview

• How the Tox e-clinching process works

• Solutions approach for the clinching process

• Solutions approach to oxide layer challenge

• Solutions approach for contact corrosion challenge

• Application samples

• E-clinching in multi-layer applications beyond two sheets

• Extreme climate and weather conditions pose significant challenges to Li battery packs, including temperature fluctuations, moisture exposure, and mechanical stresses.

• High temperatures can accelerate the degradation of Li batteries, leading to reduced performance, shorter lifespan, and safety risks such as thermal runaway.

• Cold temperatures can decrease the battery’s capacity and increase internal resistance, impacting its efficiency and overall performance.

• Moisture exposure, whether from rain, humidity, or submersion, can cause corrosion and short circuits within the battery, leading to malfunctions or even failure.

• Mechanical stresses from vibrations, impacts, or thermal expansion/contraction can damage the battery’s structural integrity and electrical connections, compromising its performance and safety.

• Adhesives can help mitigate these challenges by providing insulation, sealing, and structural support to Li battery packs. They can offer thermal management properties, preventing heat buildup or dissipation, and act as a barrier against moisture ingress. Additionally, adhesives can enhance the mechanical strength and shock resistance of battery packs, protecting them from external forces. Proper adhesive selection and application ensure improved reliability, lifespan, and safety of Li battery packs in extreme climate and weather conditions.