Quality Assurance for Battery Trays

Challenges

• Large battery tray and high number of geometric elements and weld joints quickly lead to long measurement and inspection cycles
• As the safety-critical battery tray often requires 100% monitoring, an inline solution is needed for the production environment

Your benefits with ZEISS

• Correlation-free and traceable measurement and inspection data with ZEISS Inline Solutions
• Short feature measurement times via high-end automated line sensor ZEISS AIMax cloud
• Real-time process monitoring of complex characteristics in entire battery tray

Challenges

• Thermal expansion of the battery pack when charging and driving can cause torsion and bending on the battery tray
• Numerous dimensional characteristics must be measured via random sampling or complete automated end-of-line inspection

Your benefits with ZEISS

• Multisensor measurement of large number of features with quick inspection cycles
• ZEISS non-contact optical laser scanners quickly extract feature data
• ZEISS tactile probe systems access challenging optical features such as undercuts

Challenges

• It is crucial to evaluate the complete battery tray surface, as this affects the dimensional accuracy of the entire vehicle body
• Flexible cables and connectors must be correctly positioned to ensure flawless assembly of the battery tray and cover
• Battery modules must be correctly fitted to battery compartments for safe operation

Your benefits with ZEISS

• ZEISS ScanBox enables fast automated 3D full-field measurement of the battery tray, generating a full digital twin in minutes
• ZEISS INSPECT software enables time-saving digital assembly, including all connecting components and their alignments
• Solutions provide clarity on thermal battery module deformation after cycle tests

Challenges

• Final safety check and certification of the complete battery tray poses a particular challenge
• Thermal expansion in event of temperature increases can lead to battery tray torsion and bending, causing serious safety issues

Your benefits with ZEISS

• Multisensor ZEISS CMMs feature a large measuring field that enables the use of tactile and optical sensors on a single machine
• ZEISS CALYPSO and ZEISS PiWeb software can be combined with CMMs for inline and atline comparison and correlation of results

Challenges

• Battery trays are commonly manufactured via welding and casting: risk of critical hidden defects and inner structure defects
• To identify rejects, users must be able to look inside the material and determine the size and position of these defects

Your benefits with ZEISS

• ZEISS 2D and 3D X-ray technology detects, locates, classifies, and rates internal defects as cavities, pores, and cracks
• Systems such as ZEISS METROTOM support quick, efficient, and highly detailed digitization of complex parts
• Making the invisible visible is key to identifying defective battery trays and ensuring a reliable production process