Cadillac ELR Battery Structure Welded Like Airplanes InCar Tech

11 Июн 2014 | Author: | Комментарии к записи Cadillac ELR Battery Structure Welded Like Airplanes InCar Tech отключены
Cadillac ELR Electric Cars

by Lyndon Johnson on August 5, 2013 at 6:38 pm

Ultrasonic welding, a high-tech process typically used in the aerospace and medical industries, helps ensure high quality for the new Cadillac ELR extended-range electric luxury coupe going on sale in North America in early 2014, according to a Cadillac press release. General Motors Brownstown Battery Assembly plant near Detroit uses ultrasonic welding to join metal electrode tabs on ELR s lithium-ion battery. The Brownstown battery plant uses an automated system to execute millions of these welds each year. (Jeffrey Sauger photo courtesy General Motors)


Cadillac is using ultrasonic welding technology often used in building airplanes to make the ELR battery pack s quality more uniform.

According to the press release from Cadillac. the ELR s battery pack features nearly 200 ultrasonic welds, each required to meet stringent quality requirements that enable Cadillac to offer an eight-year, 100,000-mile warranty on the ELR s battery system. The release said other advantages of ultrasonic welding include short cycle times, low capital costs, and manufacturing flexibility by use of automation.

General Motors Center for Automotive Research President and CEO Jay Baron said, Ultrasonic welding is a far superior joining technology in applications where it can be deployed. Cadillac’s innovative process will produce batteries with superior quality compared with traditional methods – and do it more efficiently. This is one example of technology development that is becoming pervasive in today’s world class vehicles.

The ELR battery packs are built at General Motors Brownstown Battery Assembly plant near Detroit, where automated ultrasonic welding is used to join metal electrode tabs on the ELR s 16.5 kWh battery system. The welding process used for the ELR was first used for the Chevrolet Volt, the release said, giving these details on how the process works:

Ultrasonic welding uses specialized tools called an anvil and horn to apply rapid mechanical vibrations to the battery’s copper and aluminum electrodes. This creates heat through friction, resulting in a weld that does not require melting-point temperatures or joining material such as adhesives, soldering or fasteners.

Cadillac ELR Electric Cars

An integrated camera vision system is used to shoot a reference image of the weld area prior to the operation to achieve pinpoint accuracy. Quality operators check electrode tabs before and after welding, and the system monitors dozens of signal processing features during each weld.

GM vice president of Global Manufacturing Engineering Catherine Clegg said, This effort is an outstanding example of teamwork between research and manufacturing engineering. It has helped integrate the use of highly technical, complex technology into a sustainable manufacturing process, which means we can consistently deliver high-quality batteries to our customers for the Cadillac ELR.

We first told you about the ELR here some time ago. Essentially a luxury sport coupe with tweaked Chevrolet Volt powertrain guts, the ELR battery pack is T-shaped and located longitudinally along the car s centerline between the front and rear wheels. The pack itself weighs 435 lbs and is 5.5 feet in length and supplies enough energy to allow the ELR to put down 295 ft-lbs of torque on-demand.

GM estimates the ELR will travel about 35 miles on electricity alone before a gasoline engine in GM parlance, a range extender kicks in to supply energy to the ELR s electric drive system.

Cadillac ELR Electric Cars
Cadillac ELR Electric Cars

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