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TWI Meets EV Battery Challenges for BMW

Thu, 10 June, 2021

TWI’s expertise in welding and joining has helped BMW solve a series of challenges related to the production of battery modules for their future electric vehicle (EV) needs.

Our experience meant that TWI was uniquely placed to help overcome hurdles associated with the fixturing and manufacture of high voltage modules, including structural welds in the module’s frame containing the cells and welding of the cell control system (CCS) to the individual cell terminals.

The work, which was to support BMW entering into module prototype production in the UK and has been supported with funding from the Advanced Propulsion Centre (APC), included tooling design and manufacture, the development of laser welding procedure specifications (WPSs) for CCS to terminal and module frame joints, validation on live assemblies, series prototype production (involving both assembly and welding) and logistics (component receipt, storage, packaging and dispatch). Additional work was done in confirming incoming cell status and a number of in-line process checks and procedures to ensure finished quality.

Paola De Bono, TWI’s lasers section manager, said, “Our technical team of design, fabrication and welding experts has worked closely with BMW to find innovative solutions to the unique challenges associated with electric vehicle battery production."

As an Industrial Member of TWI, BMW has worked closely with us over the course of several years and we look forward to continuing this relationship as we develop our EV component technology capabilities. This includes the upcoming creation of a dedicated EV centre to assist with the growth of this important area of the automotive industry.

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