Audi’s pure electric vehicle e-tron covers MLB
EVO, MEB, PPE and other vehicle platforms, the power battery and charging system used have passed 45 strict vehicle-level functional tests and 200 material tests, and are characterized by safety, environmental protection, convenience and high efficiency.
Through close cooperation with OEM engineers, Aimans has successfully applied Aimans high-performance engineering plastics to the protection device for high-voltage connection parts of battery packs, realizing the modular design of these products, and contributing to the safety of e-tron series battery packs. And longevity provides long-term protection.
Modular design: the best balance between performance and cost
The power battery pack of the e-tron series adopts the mature Cell to
Modulus has a modular design. The capacity of the battery pack can range from 55kWh to 100kWh. It can be flexibly matched according to the size of the vehicle and the cruising range. Up to 36 battery modules can be configured.
Battery modules are connected through conductive parts such as bus bars. For safety reasons, high-voltage connecting parts must be protected by insulating materials and marked as orange (RAL
2003*) so that these components can be quickly identified.
115 individual injection molded parts made of Aymans PA66 V0 material are installed in a battery module of Audi’s e-tron.
At the same time, the modular design of these components can be used in different models, reducing product development costs and achieving considerable cost benefits for OEMs.
115 individual injection molded parts made of Emmans PA66 V0 orange
Aimans’ high-performance material PA66 V0 has the following characteristics, which perfectly meets the requirements of customer battery pack application scenarios:
The e-tron battery pack is convenient and efficient to charge, and it only takes 40 minutes to charge from 5% to 80% using DC fast charging. However, in the fast charging mode, the temperature of the connecting parts between the battery modules will increase.
PA66 V0 can meet the service life requirements of more than 10 years under the working condition of 140°C.
Complies with UL-94 V0 flame retardant rating.
Durable aging test, color stability, the orange color of the part remains unchanged during the lifetime (including accidents such as fire).
After a high temperature of 140°C, the color comparison of Aimans’ PA66 V0 orange (left) and standard plastic (right)
*Note: The RAL International Color Card, also known as the RAL Color Card, is defined with a clear RAL number, allowing colors to be easily and accurately standardized throughout the world
CAE simulation predicts risks in advance, shortens product development cycle, and reduces development costs
challenges
In the initial stage of component development, the development designer will put forward the overall requirements and direction for the material of the component according to the function and working conditions.
There are often doubts about whether a specific material type can meet the function and durability indicators, especially when there is a lack of reference information in the development process of new components.
At the same time, designers also hope to get suggestions on the optimal design of product structure and mold scheme suitable for a specific material grade.
Aimans Solutions CAE
When using these new materials to design parts and molds, we provide customers with a series of supporting supports, including computer-aided engineering (CAE), mold flow analysis, structural optimization, and visualize the simulation results of molding process optimization to customers.
project results
CAE simulation shows that during the injection molding process, the polymer material in the molten state is filled into the cavity of the injection mold and the cooling process, which provides early warning of potential problems and risks and provides solutions.
CAE simulation analyzes and optimizes product structure to help customers avoid the risk of product failure.
For example, the protective cover of the high-voltage connection part of the battery pack uses the excellent anti-deformation ability of the material, optimizes the structural design through simulation calculations, and realizes the press-fit buckle connection between the upper and lower covers, which meets the requirements of repeated assembly and disassembly within the life cycle. Require.
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