The bolting process requires additional parts and specific torque values. Busbars with bolt holes can be replaced for busbar applications other than battery packs
Aluminum busbars require plated bolt holes due to corrosion
Terminals connect to solid bus bars for ease of automation
Automation is not yet fully implemented due to shielding
Welds and assemblies may require new standards and verifications
Ultrasonic welding technology is a proven joining process that car manufacturers are increasingly using for cable-to-terminal connections, busbars, battery manufacturing and power electronics in electric vehicles. Linear soldering is a more traditional and well-known technique used by all equipment manufacturers and is the standard process for splicing wires. However, like many other joining processes, linear welding has size limitations, welding difficulties in small areas and specific geometries, welding orientation issues, and vibration effects on peripheral components.