Jendamark India is a pioneer of Industry 4.0-enabled assembly lines and turnkey solutions for the automotive & manufacturing sector. Serving global Original Equipment Manufacturers (OEMs) and their Tier 1 suppliers, including MSMEs Jendamark delivers a unique combination of in-depth industry knowledge, world-class digital technologies, and high-precision engineering. Started in 1989 by Quinton Uren, in then Port Elizabeth South Africa, Jendamark entered India in 2014 and since then providing solutions to it esteemed Clients.
With its focus on TECH And PEOPLE, Jendamark has become a beacon for companies in developing economies to supply world class solutions to developed economies, thus supporting the overall economic growth as well.
The Importance of Process Security in EV Assembly Lines
The transition from internal combustion engine vehicles (ICEs) to electric vehicles (EVs) marks a significant shift in automotive technology. While ICEs rely on combustion engines powered by gasoline or diesel, EVs use electric motors driven by batteries. This shift brings notable advantages, including lower running costs and reduced environmental pollution. However, EVs also introduce new complexities in assembly, emphasizing the importance of process security.
Key Components in EV Assembly
EVs consist of numerous electronic components and a complex network of wires connecting the battery pack and motor. These components contribute significantly to the vehicle’s weight and cost, with the battery pack alone accounting for over 50% of the total. Unlike ICEs, where the cylinder block serves as the main structural component, EVs depend on various critical elements like inverters, Battery Management Systems (BMS), and Motor Control Units (MCU). These systems are the brains of the vehicle, managing essential functions and requiring meticulous assembly to ensure reliability and safety.
For instance, the assembly of small electronic components in inverters, BMS, and MCUs necessitates protection against Electrostatic Discharge (ESD). Additionally, the handling of tiny bolts is streamlined using bowl feeders, which improve efficiency and reduce the risk of damage.
Motors in EVs, acting as the vehicle’s muscle, operate on electromagnetic induction. The high-strength magnets used in these motors are fragile, making manual assembly risky. Jendamark has developed automatic stations for magnet insertion, eliminating errors and enhancing safety.
Battery packs, the heart of an EV, are assembled from various types of cells (cylindrical, prismatic, and pouch). Proper handling is crucial to avoid electrical short-circuits and cell damage. Jendamark’s robotic grippers ensure error-free handling, and busbar separators prevent short-circuits during manual connections.
Process Security with ODIN Workstation
In India, a significant portion of the workforce is contract-based, leading to a lack of training and expertise. This issue is compounded by the complex nature of EV assembly. Jendamark addresses these challenges with the ODIN Workstation, a software solution that streamlines production training and guidance. The ODIN Workstation reduces training periods from weeks to days, provides step-by-step instructions on an interactive touch screen, and ensures adherence to process steps, preventing mistakes and improving product quality.
Compliance with AIS 156 Standards
The Indian government has introduced AIS 156 standards to regulate EV manufacturing, particularly battery packs. These standards mandate the storage of cell grade and parameter data, such as Open Circuit Voltage (OCV) and Internal Resistance (IR), to ensure quality and safety. Jendamark’s ODIN Workstation records and controls this data, facilitating compliance with AIS 156 requirements. The system also integrates with testing machines to store data and verify that battery packs meet the necessary standards.
The Role of Laser Welding in EV Assembly
Laser welding is a critical process in EV battery manufacturing, offering several advantages over traditional welding methods. It reduces thermal energy input, lowers transition resistances, and improves overall performance. Key considerations in laser welding include:
• Clamping Method: The choice between welding masks and single cell clamping affects production efficiency and adaptability.
• Precise Cell Positioning: Consistent and precise cell positioning is crucial for uniform welds.
• Busbars Design: Design considerations impact both tooling and the welding process.
• Robust QA Process: Real-time weld measurement technology ensures high accuracy, comparable to destructive testing.
