APRIL 202319India is among a handful of countries that supports the global EV30@30 campaign, which aims for at least 30 percent new vehicle sales to be electric by 2030System to must be designed to have no resistance imbalance across conduction path. To achieve this, Current Collector Assembly must be designed to have uniform current density. Battery Interconnect System needs to be kept under specified max. temperatures and as much as possible, it needs to have uniform temperature distribution across conduction path and lowest T from most +VE to most -VE. Selection of Material is an important criterion to achieve function, weldability with cells that drives cost. Cell level fusing (maximum safety) is the most challenging part of Battery Interconnect System applications & Design.Mechanical Performance: Battery Interconnect System to be able to withstand Vibrations and shocks offered by various driving conditions.Fit: Battery Interconnect System needs to be fit within the space constraints provided by battery pack manufactured.Often this will be conflict with electrical performance and cost. There will challenges to fit Battery Interconnect System within boundary conditions that meet Electrical, Mechanical performances and cost targets. If Current Collector Assembly is welded both +VE and -VE on same side of a cell, the challenge is to separate them to avoid short circuit at all operating conditions and provide sufficient dielectric strength.Form: Current Collector Assembly design needs to be able to weld with cells. Achieving intended weldability ensure greater electrical performance of the battery pack. Limitation on the thickness of the Current Collector Assembly due to weldability factors calls for careful consideration of the material thickness that is compatible for welding method chosen.Manufacturing: Challenges in manufacturing remain mostly same as general manufacturing practices, but as the process includes stamping, cleaning, welding, molding, assembly and so on. special focus needs to be given to the cleanliness aspect as any oil contamination will impact the weldability of interconnects between Copper & Nickel and welding with the cells. Quality of the stamping and welding needs to be monitored for burr free parts & consistent welds. Based on our experience we find the startups very aggressive on the design aspects, but when it comes to design for manufacturability, they get stuck and must fall back on experienced players in this field. To support the startups & customers, we have established our development team who based on our manufacturing, design & development expertise get involved at the initial stages of development with the startup designers and help them consider the manufacturing aspect of the interconnects to reduce the iterations & shorten development lead times. This also helps them to evaluate the cost & optimise during the development stages of their projects.
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