This is how battery trays are made

The battery tray of an electric vehicle plays a central role, as it contains the battery, the heart of a purely electric or hybrid vehicle. In addition to the obvious task of enclosing and supporting the battery cells, safety-related requirements combined with weight and cost optimization pose the greatest challenge. Welded or die-cast aluminum trays are the method of choice because they can be mass-produced cost-effectively with low weight and high strength. Aluminum is also nearly 100% recyclable, underscoring the sustainable solution of e-mobility.

Battery trays for purely electrically powered vehicles (BEV = battery electric vehicles) are assembled and welded from individual extruded profiles, with these trays usually already constituting the complete vehicle floor.

This is how battery trays are milled

1. High flexibility due to universal clamping devices Universal clamping devices allow the clamping of different profiles, e.g. side profile, front profile, rear profile, etc. without retooling the machine. 2. measuring of the profiles Measuring of the profiles: Due to the tolerances from the extrusion process, it is necessary to measure individual geometries using probes or lasers before the first machining operation. 3. Double machining of the individual profiles Precise machining is carried out in double spindles in the ANGER SP2-P or SP2-A. Both machine types can be loaded and unloaded in parallel during machining, thus ensuring maximum output rates. 4. Assembly of the battery tray After the individual parts have been machined, the parts are assembled and welded in welding cells to form complete battery trays. 5. Finishing of the battery trays After the welding process, finish machining is performed in an ANGER SP2-P or SP2-D, depending on the battery tray size, in synchronous double machining or with two independent spindles on one component.
Battery trays

Manufacturing battery trays for hybrid vehicles

  • Due to the more complex shapes, more complex tolerances and thin wall thicknesses, the clamping system of cast trays is of particular importance. Here, it is necessary to find the optimum of clamping forces, vibration damping and deformation with simultaneous flexibility (e.g. OP10 and OP20 in one clamping device).
  • Depending on the required tolerances on the finished part, the blank must also be measured here by means of a probe or laser.
  • The machining is done on the ANGER SP2-P or SP2-D. Both machines allow the synchronous double machining of two components or the machining of a very large component with two independent machining spindles.

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