In recent years, the new energy vehicle industry has shown a booming development trend and has become an important direction for the transformation of the global automotive industry. With the enhancement of environmental awareness and strict restrictions on emissions of traditional fuel vehicles, new energy vehicles have received widespread attention from consumers and strong support from the government with their advantages such as zero emissions and low noise.
From the development trend, new energy vehicle technology continues to innovate, the cruising range is gradually improved, the charging facilities are increasingly improved, and the degree of intelligence is getting higher and higher. The market prospects are very broad. It is expected that the sales volume of new energy vehicles will continue to grow and the market share will continue to expand in the next few years.
However, the new energy vehicle industry also faces some challenges. For example, the high cost of batteries limits the popularity of new energy vehicles; the construction of charging infrastructure still needs to be further strengthened to meet the needs of consumers; in addition, the safety and reliability of new energy vehicles also need to be continuously improved.
However, challenges and opportunities coexist. The government’s policy support has provided a good development environment for the new energy vehicle industry, and enterprises are also continuously increasing their R&D investment to promote technological progress. At the same time, consumers’ increasing attention to environmental protection and energy conservation has provided a strong impetus for the development of the new energy vehicle market. Against this background, the new energy vehicle industry is expected to usher in a more brilliant future.
Principle of Ultrasonic Welding Technology
Basic principle:
Ultrasonic welding connects materials based on high-frequency vibration, energy transfer and molecular friction. During welding, the ultrasonic generator generates high-frequency electrical energy, which is converted into high-frequency mechanical vibration by the transducer and transmitted to the surface of the material to be welded through the welding head. Under the action of high-frequency vibration, intense friction occurs between the material molecules, which is then converted into heat energy. As the heat energy increases, the temperature of the material contact surface rises, and after reaching a certain level, the material begins to soften and melt. At this time, a certain pressure is applied to make the two parts of the material tightly combined.
In this process, the physical state of the material gradually changes from a solid state to a viscous flow state, and finally cools and solidifies to form a firm welded joint. The whole process is efficient and precise, and can complete welding in a short time, reducing the thermal impact on the material.
Ultrasonic Welding Technical features compared with traditional welding
| Comparison items | Ultrasonic welding | Traditional welding |
| Efficiency | No need for preheating and cooling, fast welding speed, can greatly improve production efficiency, and significantly shorten the cycle in large-scale production. | Preheating may be required before welding and cooling may be required after welding, resulting in low production efficiency. |
| Accuracy | No need for additional solder, the solder joints are precise and uniform, which can effectively avoid thermal deformation or performance degradation of the material. | The heat-affected zone is large, which can easily affect material properties and make it difficult to control the uniformity of welds. |
| Environmental protection | It is a smokeless and fireless cold processing process, which avoids the generation of smoke and harmful gases and meets environmental protection requirements. | It may produce pollutants such as smoke and harmful gases, which have a certain impact on the environment. |
| Material adaptability | It is suitable for welding connections of different materials such as copper and aluminum, and can meet the welding needs of various material combinations. | Poor adaptability to welding of different materials, and different processes and equipment may be required. |
| Cost | In large-scale production, fast welding can reduce production costs and the equipment is cost-effective. | Equipment costs, energy costs and subsequent processing costs may be high. |
Reasons why the new energy vehicle industry chooses ultrasonic welding
Improve production efficiency:
Ultrasonic welding has greatly improved production efficiency in the production of new energy vehicles. The welding process does not require preheating and cooling, and the welding operation can be completed quickly, greatly shortening the production time of a single product.
In large-scale production, the advantages of this fast welding are more obvious, which can significantly shorten the entire production cycle. Moreover, ultrasonic welding technology is mature and there is almost no development period. Enterprises do not need to spend a lot of time and energy to develop and debug new welding processes, and can quickly put them into production.
In addition, it can also optimize the production line, reduce waiting time and unnecessary processes in the production process, make the production line smoother and more efficient, thereby increasing overall production capacity and meeting the market’s growing demand for new energy vehicles.
Improve welding quality:
Ultrasonic welding can effectively improve the welding quality of new energy vehicles. This welding method does not require additional solder, and the welds are precise and uniform, making the welds more solid. During the welding process, since thermal deformation or performance degradation of the material is avoided, deformation and cracks can be reduced, and the stability and reliability of the welding parts can be guaranteed.
For key components of new energy vehicles, such as battery systems and electronic control systems, high-quality welding is essential. Good welding quality can improve product performance and safety, reduce the probability of failure, extend the service life of the product, and provide a solid guarantee for the quality of new energy vehicles.
Reduce energy consumption:
Ultrasonic welding has significant advantages in terms of energy consumption. It achieves welding through direct transmission of vibration energy, reduces energy waste, and can save a lot of energy compared to traditional welding methods. In large-scale production, energy saving means cost reduction, and enterprises can effectively control production costs while ensuring product quality.
At the same time, this energy-saving welding method also contributes to environmental protection. It is a smokeless and fireless cold processing process, which avoids the smoke and harmful gases generated by traditional welding processes, meets the strict requirements of current environmental protection production, and helps the new energy vehicle industry achieve green and sustainable development.
Adapt to a variety of materials
A variety of different materials are used in new energy vehicles, and ultrasonic welding has good adaptability to these materials. Whether it is plastic or metal, such as copper, aluminum, etc., ultrasonic welding can achieve stable and reliable connections.
- For plastic materials, it can achieve high-strength welding to ensure the integrity and sealing of components.
- In terms of metal welding, it can cope with components of different thicknesses and shapes, such as battery tabs, copper and aluminum bars, etc.
- Different materials can obtain good welding effects under ultrasonic welding, with high weld strength and good conductivity, which can fully meet the performance requirements of new energy vehicles for different components, and provide strong support for the diversified design and manufacturing of new energy vehicles.
Application cases of ultrasonic welding in new energy vehicles
Battery system welding
Ultrasonic welding plays a vital role in the battery system of new energy vehicles. The welding of the battery shell is a key link to ensure the safety and stability of the battery. Ultrasonic welding can achieve a firm and sealed connection, prevent the leakage of electrolyte inside the battery, and provide reliable physical protection for the battery.
As a key component for connecting the battery to the external circuit, the welding quality of the pole ear directly affects the battery performance. Ultrasonic welding can ensure welding strength and conductivity, effectively avoid the hidden danger of short circuit inside the battery pack, and ensure the charging and discharging efficiency and safety of the battery.
Copper-aluminum bar welding is also an important part of the battery system. Ultrasonic welding is particularly suitable for the welding of copper-aluminum bars and the connection of copper-aluminum metals, providing a reliable solution for the conductive connection inside the battery pack.
Electronic control system
Welding ultrasonic welding is also widely used in the electronic control system of new energy vehicles. The welding of the controller box needs to ensure good sealing and stability to protect the internal electronic components from the influence of the external environment.
Ultrasonic welding can achieve precise welding, ensure the structural integrity of the controller box, and provide a stable working environment for electronic components. The welding of conductive plastic parts is equally important. It can achieve reliable electrical connection and ensure the accurate transmission of electronic signals.
Body structure welding
Ultrasonic welding also shows unique advantages in the body structure of new energy vehicles. The welding of interior parts requires beauty, firmness and environmental protection. Ultrasonic welding can meet these requirements, achieve seamless welding, and improve the overall quality of the interior. The welding of wire harnesses is the key to ensuring the normal operation of the electrical system. Ultrasonic welding can achieve stable electrical connections and avoid problems such as loose wire harnesses and poor contact. The welding of lightweight metal components is crucial to reducing the weight of the vehicle body and improving energy efficiency. Ultrasonic welding can reduce the thermal impact on the material while ensuring the welding strength and maintaining the original performance of the metal components.
Development trend of ultrasonic welding technology
Technological innovation
Ultrasonic welding technology is developing in multiple innovative directions. The development of high-performance welding heads is one of the keys. New welding head materials and designs can improve welding accuracy and efficiency, reduce wear and extend service life. Multi-material welding is also an important trend. With the diversification of materials used in new energy vehicles, high-quality welding between different materials has become an inevitable requirement.
In addition, AI empowerment has brought new changes to ultrasonic welding (applicable to production line ultrasonic welding). Through real-time monitoring and adjustment of the welding process by artificial intelligence algorithms, welding parameters can be automatically optimized to improve the stability and consistency of welding quality. These technological innovations will promote the wider and deeper application of ultrasonic welding in the new energy vehicle industry, and improve the production level and product quality of the entire industry.
Application expansion
The application expansion prospects of ultrasonic welding technology in the new energy vehicle industry are broad.
- In the field of charging piles, it can be used for welding of charging modules, cable connections and other components to improve the reliability and safety of charging piles.
- In terms of energy storage batteries, ultrasonic welding can meet the welding requirements of battery modules and PACKs and improve the performance of energy storage systems.
However, application expansion also faces some challenges, such as the special requirements of different application scenarios for welding processes, market awareness in new fields, etc. But the opportunities are equally huge. With the continuous development of the new energy vehicle industry, the market demand for charging piles and energy storage batteries continues to grow, providing more application space and development opportunities for ultrasonic welding technology.
Improved standards:
The standards related to ultrasonic welding technology are constantly being improved. Industry standards clarify the specifications of welding processes, equipment performance, etc., so that companies have rules to follow in production. Quality standards strictly stipulate key indicators such as the strength and conductivity of welded joints to ensure the stability and reliability of product quality. The improvement of standards has played a positive role in promoting the development of the industry. It helps to improve the overall level of the industry, regulate market competition, and protect the rights and interests of consumers. At the same time, unified standards are also conducive to technical exchanges and cooperation between enterprises, and promote the healthy and sustainable development of ultrasonic welding technology in the new energy vehicle industry.
