The shift toward electric vehicles (EVs) from internal combustion engine (ICE) automobiles has disrupted automotive manufacturing. Automotive engineers have been compelled back to the drawing board to design these new vehicles for the most pleasant driving experience possible and transform their production facilities to meet the new demand.
Our Kenona facility is well-poised to meet the evolving design criteria for EVs and can act as a single source in your EV parts and components supply chain. Here are some of the design and manufacturing challenges our engineers can handle with precision and efficiency.
Automotive Batteries
EVs have changed how batteries affect a vehicle’s performance, range, and efficiency, with key design determinants becoming scalability, production cost, and durability.
Additionally, the battery’s pivotal role in the EV’s performance has necessitated a change in the design of the car’s chassis to accommodate and protect it. Unlike smaller, lighter, and square-shaped ICE batteries, EV batteries use a “skateboard” approach to sit in the chassis for safety and convenience.
Building Materials
Using lightweight building materials helps the battery maximize the vehicle’s range. As most ICE vehicles are made from 100 percent steel, we use multi-material strategies to meet the EV’s performance needs.
Steel plays a reduced role in EVs but is still used in the chassis, body panels, and specific structural components. However, carbon fiber is also prominently featured in the EV’s design due to its strength and light weight.
Light plastic is used for the bumpers, interior trim, and some panels, while copper is used for electrical wiring and components such as the electric motor and battery pack.
Charging Systems
The EV’s charging system requires several components to work together seamlessly to ensure efficient, safe, and user-friendly energy delivery.
Critical considerations in the charging system design include drawing AC power from the grid and converting it to DC power for the battery (which converts it back to AC to operate the vehicle), cooling systems to stop the battery from overheating during charging, conforming to global connector standards, an easy user interface, and much more.
We ensure that electrical protections, such as ground fault detection, surge protection, and overcurrent prevention, are included in the design. Designs are also required to adhere to IEC, UL, or SAE standards for electrical and mechanical safety.
Cabin Acoustics In EVs
The engine in ICE vehicles makes noise, blocking out other external noises. However, EV engines are generally quiet, and the composite material the chassis is composed of tends to amplify sounds. These challenges have prompted EV designers to address noise, vibration, and harshness (NVH) issues.
Some of the innovations introduced to stop external noise from impacting the driver and passenger experience include:
- Integrate high-performance insulation, sound-absorbing materials, and advanced chassis tuning into the design to muffle external sounds and high-frequency noise from the motor and electronics
- Optimizing aerodynamics and using dealing techniques to cut wind noise
- Install sound-deadening mounts to isolate and absorb vibrations from the motor and inverters
EVs are virtually silent at low speeds, so many designers include Acoustic Vehicle Alerting Systems (AVAS) that emit artificial sounds to promote pedestrian safety
Many EVs also offer artificial sounds in the cabin, such as a revving engine when the driver steps on the gas pedal. This feature replicates sound typically associated with ICE vehicles while blocking out unwanted noise from within and without the EV.
Reducing Weight With Aluminum Extrusions
Another strategy to keep the EV as light as possible is fabricating parts with aluminum extrusions, which offer exceptional reliability, durability, and performance benefits that help optimize vehicle efficiency, range, and energy consumption.
Although aluminum can be used to create various EV components, one of its more popular uses is for battery enclosures. Aluminum helps create a natural electromagnetic shield that prevents interference with the vehicle’s other electronic components, allows better energy absorption in an accident, and helps protect the battery from damage caused by temperature variations and sudden shocks.
Additionally, extruded aluminum offers superior flexibility and formability during the fabrication and assembly processes compared to steel or carbon fibre.
EV Assembly
Production lines for EVs are significantly different from those for ICE vehicles due to the unique sizing and configurations of EV parts. For example, we’ve optimized the complex integration process of the battery pack, electric motor, and other components to ensure optimal EV performance and safety.
Furthermore, advanced lightweight composite parts can be challenging to work with due to their high spring back. Automation supported by Kenona’s robot technology can help mitigate the risk of damaged parts during assembly, improve process efficiency, and reduce completion time.
Read More: How Robotics Is Transforming The Precision Machining Industry
Kenona Industries: Your Partner In Quality EV Parts And Components
Since 1988, the Kenona Industries/Arrow Automotive team of automation engineers, controls engineers, software engineers, and robotics experts have integrated the latest technology in our machining cells to fabricate high-volume, precision-made components for gas-powered and electric vehicle components.
We specialize in fabricating complex, cost-effective metal design and fabrication solutions, built by a team with the skills, experience, and knowledge to always bring you the best results.
When you need quality precision machined parts and components, call Kenona Industries first.
Contact Kenona Industries For A Quote On Your Next Design And Fabrication Project
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