New Hyundai-Kia EV battery welding system earns acclaim

[Photo by MK DB]

As the need for new battery-welding systems and facilities grow alongside a surge in the number of electric vehicles (EVs), Hyundai Motor Group developed an innovative battery-welding system that meets the evolving demands of EV manufacturing to much acclaim.

A dual welding system specifically tailored for EV batteries, developed by Hyundai Motor Co. in collaboration with Kia Corp., garnered 2024’s 15th-week award from the Industrial Research 52 Jang Young-shil award.

Battery welding presents unique challenges that are different from conventional precision machining assembly methods. Pouch batteries are susceptible to damage from external forces, for example, potentially leading to short circuits or fires. Sparks generated during welding processes, which can lead to quality degradation, also require periodic cleaning, but the cleaning process is extremely dangerous due to the need to access confined spaces.

Hyundai Motor’s system introduces a revolutionary integrated fixture capable of accommodating batteries of any size or type. By consolidating multiple welding processes into one, it reduces the need for multiple fixtures, enhancing efficiency.

Unlike previous models requiring manual fixture ejection, this system automates the process, enhancing safety and enabling easier maintenance. Featuring a parallel configuration, the system ensures uninterrupted production, even in the event of robot malfunctions or maintenance requirements and this design enhancement yields a significant 29 percent boost in productivity compared to previous iterations.

Proactive fire suppression mechanisms also minimize potential production losses and secondary hazards such as toxic gas emissions.

This award-winning product boasts high productivity in EV battery welding systems, holding patents in major global markets, solidifying its technological prowess. Launched in 2022, it achieved notable sales figures domestically and internationally, with projected revenues at 400 billion won by 2026.

The IR52 Jang Young-shil award, given by the Ministry of Science and ICT and organized by Maeil Business Newspaper and the Korea Industrial Technology Association, recognizes novel and valuable contributions to industrial innovation.