Challenges
As with any new technology, battery welding brings its own unique set of problems and challenges to overcome. Primarily among these challenges were those related to health and safety, with particular regard to the containment, control and management of thermal events.
This challenge required a reactive approach, as demanded by the automotive market, alongside knowledge sharing and training with the emergency services. With a tailored project management approach, which encompassed frequent scope deviation, TWI undertook direct laser hit trials and chemical analysis based around the exposure of thermal events.
With a fast-paced approach to the challenges of battery welding, TWI needed to demonstrate an ability to think on its feet while maintaining a professional client relationship.
This flexible approach included frequent communication in order to inform our clients of progress as they aimed to complete the project as quickly as possible. This requirement for a speedy delivery is in line with the automotive industry’s desire to remain competitive by delivering new vehicles to market in as short a timeframe as possible.
In addition, TWI had to overcome design and manufacturing challenges related to existing design limitations associated with already constrained component parts, which required bespoke handling and alignment tooling. Once this tooling had been tested and proven to work it was further developed for prototype production purposes.