The battery pack combines all components of a battery system and represents the heart of an electric car. TRUMPF provides a unique complete solution for electromobility for the tightness, crash safety, productivity and flexibility requirements. This means that you can weld all interior components as well as the battery housing with a high degree of precision – and always with process reliability thanks to an intelligent sensor system. The laser as a precision tool provides innovative solutions for the production and integration of the cooling system. Sheet metal components in the battery pack can be manufactured with networked system solutions of TRUMPF machine tools. For example, the battery tray is laser cut, reshaped and laser welded.
The battery system must be protected against external influences to guarantee its function is long-lasting and high-performance. The component is brought into its final form with laser cutting, edge-forming, punching and bending processes. Surfaces are cleaned and structured and paints are removed to ensure safe sealing and electrical grounding.
TRUMPF machine systems process flat sheet metal by laser cutting, bending, punching dies and laser welding to create a gas-tight battery tray – depending on the requirements, this can also be done within a fully automated process. Seamless documentation, repeatability and traceability are a matter of course in the production process. Our experts will advise you from design to production and even beyond.
Lasers are the optimum tool for creating mechanically robust and highly conductive connections between live components (busbars). TRUMPF offers complete solution packages for battery pack production, from 2D laser cutting to bending and joining the module housing. High repeatability and low-spatter join connections ensure a cost-efficient production.
Lasers can be used in various industrial applications, ranging from drying the electrodes, precision cutting and welding of foil stacks to connect the cell conductors. TRUMPF has a unique laser portfolio for all battery cell applications, including lasers with green and infrared wavelengths, active beam formation as well as single and multi-mode lasers.
A laser is used for energy-efficient welding of live connections such as busbars and powerbars. Processing times and spatter formation are minimized with BrightLine Weld. This ensures that every part is a good part. Marking lasers are used for clear and permanent component marking.
An essential part of the battery pack is the cooling and heating system. Whether plate heat exchangers, pipes or punch press profiles, TRUMPF offers the suitable production system for every design and material. This creates the optimum surrounding conditions for a reliable and high-performance battery pack.
A stable supporting structure is essential for the best possible protection of the complex battery pack. Crash-optimized designs of flangeless connections can be implemented with the TRUMPF machine portfolio. This makes it possible to manufacture a particularly stable and simultaneously light supporting structure.
A stable frame is used to position the battery module in the battery tray. TRUMPF offers a wide spectrum of solutions for many joining tasks. An optimum system for quick and automated production is created with scanner optics in combination with OCT seam position detection, for example.
To prevent or deflect possible damage to the battery system, a surface-covering and extremely resistant protection is required. TRUMPF components can be of excellent use in applications such as partial reinforcement by laser metal deposition or welding of high-tensile materials with scanner optics.
TRUMPF stands for industrial production solutions for the manufacture of all battery pack components. The combination of TRUMPF expertise in the advantages of laser technology with the flexibility of sheet metal processing provides customers with perfect solutions for the economic production of battery pack components.
Thanks to energy-minimized, wear-free laser processing, it is possible to produce structural components with optimum stability. Not only that - the laser is also unbeatable in terms of weld seam quality, tightness and inspection effort. Furthermore, a comprehensive system of sensors constantly monitors the quality of the weld seams and ensures a precise welding depth.
We cover the entire sheet metal process chain with our many years of comprehensive expertise in sheet metal processing. Our 2D laser cutting machines, bending machines and laser welding cells are used for the fully automated production of battery trays in networked processes, for example.
Would you like to produce high-tensile and helium-tight weld seams without thermally deforming the component? Thanks to innovative process management such as oscillation welding (wobbling) or new laser technologies like BrightLine Weld, TRUMPF is opening up the necessary design scope for the entire material variety of battery packs. TRUMPF provides the customized laser technology for every laser-supported welding process such as laser-hybrid welding, for example.
Whether paints, oils, greases or smoke residue, TRUMPF offers diverse cleaning solutions for contamination, which is absolutely mandatory to ensure technical cleanliness for adhesive bonding preparation. It is possible to prepare the most varied of geometries with our lasers and corresponding scanner optics.
TRUMPF lasers mark battery system components permanently and gently with high-contrast markings, for example with clear QR codes for part identification. TRUMPF VisionLine image processing makes it easy to check the marked code.
Would you like to know how we can provide you with optimum support on your path to electromobility? Make an appointment directly with our internationally active branch managers. They are happy to advise you concerning our customized complete packages and facilitate new production technologies for the new mobility.
Whether it is cutting, bending or welding – TRUMPF offers everything from one source. You can process components selectively with the laser precision tool. This means in practice: the TRUMPF laser can be flexibly integrated into the process chain chronology. The components are only processed point by point, surrounding areas remain untouched, or are not damaged during cleaning, for example.
Do you need support? Our industry experts and application engineers in the TRUMPF Laser Applications Center and Customer Center carry out feasibility tests, provide you with recommendations for concrete implementation and always find the correct parameters for your application. Compared to other laser manufacturers, we also support you in networking your laser systems - regardless of whether you are already taking big steps or are just starting out on the path to your company's networked future.
Welding, bending, cutting, cleaning and marking – TRUMPF facilitates a comprehensive networked solution for all individual tasks, enabling seamless component traceability as well as a barrier-free development for the consolidated process chain.
Benefit from our decades of application experience for the different part processes and their technical implementation: our laser machines, inter-machine communication and innovative sensor technologies facilitate the continuity of the process chain and constant quality monitoring.
The Condition Based Services increase the technical availability of your laser systems. Use dashboards to visualize the state of the machine - Smart View Services. The TRUMPF Condition Monitoring Center evaluates sensor data and detects failure risks.
You receive relevant data concerning your laser using the Data Based Services. The OPC-UA interface provides important information for this purpose. The Quality Data Storage 2 software also makes it possible to record data synchronously to the process.
Does every new beginning have to be difficult? Not with TRUMPF. For we know how you can reduce your high start-up expenditures: our designated TRUMPF industry experts are at your side with a thorough and customized process and application consulting service.
Individual customer parts are manufactured in TRUMPF precision machines and are checked to ensure they meet the material requirements. We identify the optimization potential in the production of your part along with you. The goal: we will optimize and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively.
What potential is still hidden in your parts? Discover it for yourself: in our workshops and seminars on part optimization in sheet metal and tubes. You will trim your parts for success with our consolidated expertise in sheet metal design - and save money as well. For economically constructed parts are the key to efficient manufacturing, require fewer process steps and pave your way toward networked production.
No two productions are the same. This is why your path to the Smart Factory is also unique. Consultancy for networked production is precisely where we come in. No matter whether you are already making great strides into the networked future of your company or you are just starting out – with a strong, competent partner by your side, it will be easier to walk into your automated future. No two paths are the same because TruConnect combines individual components to provide customized solutions for you.
We ensure TRUMPF products are an all-embracing experience for our customers.
Whether it is in the TRUMPF Laser Applications Center or Customer Center –& our experts in Ditzingen will show you what is possible – in person and in line with your requirements. Our application specialists and industry experts will support you during application development and optimization of your specific component in the Laser Applications Center, a center extending over an area of 4000 m². On the other hand, you will experience the entire sheet metal process chain – from programming to laser welding – in our Customer Center. We offer individual guided tours as well as live demonstrations of the technologies. Time studies, feasibilities and generation of sample parts are also part of the core tasks.
