EB-Bat - Electron Beam Battery Welding

汽车制造业对英国经济很重要，营业额达820亿GB，直接雇用16.9万人。2018年，英国汽车生产工厂生产了271万台内燃机(ICE)，在欧洲排名第四，雇佣了11,500名员工，营业额为85亿GB。然而，汽车行业正面临着未来十年内燃机产量将下降的挑战，因为由于对零尾气排放的要求、消费者需求和政府监管，电动汽车将被电动汽车取代。在电动汽车中，电池组是汽车最昂贵、最难大规模可靠生产的部件。许多汽车制造商正在转向使用圆柱形电池(直径通常为22毫米，长度为70毫米)，而不是袋式或棱柱式电池。圆柱形电池具有能量密度高的优势，可以提供更大的行驶里程，更大的损伤容忍度和安全性，以及更快的充电率。一辆典型的电动汽车在电池和母线之间将有大约12,000个接头，通常每30秒就有一辆车从工厂的生产线上下来。这带来了独特的制造和生产率挑战。传统焊接(通常是引线键合、电阻点焊、微型TIG/脉冲电弧)可以制作这些接头，但速度很慢，因为需要多个平行工位，增加了资本和运营成本。最近，激光焊接已经部署使用振镜光束偏转(扫描)和重新聚焦；提供了更高的生产率，尽管用于母线(铜和铝合金)的材料由于反射率而固有地难以激光焊接，并且扫描的速度受到光学可以机械调节的速度的限制。在单一故障可能危及电池组寿命性能的情况下，批量激光焊接方法的废品率很高，这导致了几次备受瞩目的产品召回。EB-BAT项目将演示使用一种被证明比激光焊接快20倍的工艺制造电池组。EBS可以比激光更快地偏转和重新聚焦，因为这是通过磁场实现的，在焊接时不需要移动部件。此外，EBS不会受到铜和铝的反射率的影响，从而使焊接更加一致和可靠。EB-BAT项目将向汽车制造业提供令人信服的工艺性能、生产率、质量和经济证明，目的是确保资金投入生产。

The automotive manufacturing sector is important to the UK economy, with a turnover of £82 billion, directly employing 169,000 people. UK automotive production plants produced 2.71 million internal combustion engines (ICE) in 2018, 4th in Europe, employing 11,500 with £8.5 billion turnover. However, the automotive industry is facing the challenges that ICE production is set to decline over the next decade as they are replaced by EVs due to requirement for zero-tailpipe emission, consumer demand and government regulation.In EVs, battery packs are the most expensive and difficult part of the vehicle to reliably manufacture at scale. Many car manufacturers are moving towards using cylindrical cells (typically 22mm diameter and 70mm long) rather than pouch or prism cells. Cylindrical cells offer the advantage of high energy density, giving greater vehicle range, greater damage tolerance and safety, and faster charge rates.A typical EV will contain some 12,000 joints between cells and bus bars, and typically a vehicle will roll off a plant's production line every 30 seconds. This presents a unique manufacturing and production rate challenge. Conventional welding (typically wire bonding, resistance spot, mini-tig/pulsed arc) can make these joints, but only at a slow rate, as such multiple parallel stations are needed, adding to capital and operational costs. More recently, laser welding has been deployed using galvanometer mirror beam deflection (scanning) and refocussing; offering higher production rates, although the materials used for bus bars (copper and aluminium alloys) are inherently difficult to laser weld due to reflectivity, and the speed of scanning is limited by the speed with which the optics can be mechanically adjusted. In the scenario where a single failure can compromise the lifetime performance of the battery pack, high rejection rates have been experienced with volume laser welding approaches, which has caused several high-profile product recalls.The EB-Bat project will demonstrate battery pack manufacture using a process shown to be potentially x20 times faster than laser welding. EBs can be deflected and refocussed much more rapidly than laser beams, as this is achieved using magnetic fields, without moving parts as the welds are made. In addition, EBs do not suffer from reflectivity from copper and aluminium, making more consistent and reliable welds.The EB-Bat project will provide a compelling demonstration of the process performance, productivity, quality and economics to the automotive manufacturing sector with an aim to secure funding to take it into production.