As the transition to a more sustainable future continues, more Americans are discovering the advantages of electric vehicles (EVs). From limited maintenance to incredible torque, acceleration, the ability to fuel from home, and attractive rebates, EVs are no longer just a “green” vehicle option but an aspiration with broader appeal.
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With battery electric vehicles (BEVs) accounting for 70% of electric car sales, original equipment manufacturers (OEMs) and tier one suppliers are upgrading facilities to make them EV production-ready. This is especially true for the North American market, where sales for electric vehicles are expected to expand at a compound annual growth rate (CAGR) of 18.2% by 2028. Moreover, EV sales in the U.S. are expected to approach two million units for 2024, accounting for 13% of new car purchases, according to Bloomberg.
Adapting product portfolios
Along with the push for electric vehicles, however, a huge manufacturing shift is taking place that is prompting automakers and their suppliers to evaluate their product offerings. From starter and exhaust systems to alternators, gas tanks, radiator coolant systems, and more, the type and volume of parts needed for internal combustion engines continue to dwindle. To effectively deal with this margin erosion and keep profitable, motivated tier one suppliers are turning “out with the old” attitudes into strategic, “in with the new” game plans that can ride the electric vehicle tsunami into a more competitive future.
Designed around grasping a larger piece of the manufacturing/value-chain puzzle, select suppliers are moving from mainly piece-part manufacturing to complete system production to better accommodate EV production. From full powertrain and battery assemblies, the idea of making entire vehicle systems at one facility holds promise.
With this undertaking, however, comes a warning: Most likely, the assemblies and systems produced at each site won’t be designated for mass production because most electric car makers offer signature EV designs. Throw in the complexity of battery-only electric models vs. hybrid options (among others), and even more pressure is added to suppliers facing margin compression. That said, suppliers should research market and OEM needs, and execute a clear-cut plan for what is ultimately produced.
Although manufacturing select parts will be greatly minimized, some parts, such as seats, restraints, shocks, and brakes, will face little to no change. Another concept for tier one suppliers to consider is manufacturing new mechanical systems or unique features. Heat pumps, for example, are becoming common for EV HVAC installation because heat pumps are far more efficient on battery power compared to electric-element heaters.
Likewise, high-voltage battery systems to enable faster charging are being manufactured. Because these batteries can be heavy, light weights elsewhere are extremely important. As a result, giant high-pressure die-casting machines are being used to punch out aluminum vehicle chassis. Known as gigacasting, this process is spreading throughout OEMs, with several tier one suppliers jumping in to fulfill demand. While this process and these reduced weight chassis are meeting a niche requirement, they also substantially reduce the use of traditional car chassis consisting of dozens of welded body parts. Overall, this minimizes production time.
Suppliers will need to take stock of their current production offerings and adjust accordingly to remain relevant in an EV manufacturing world.
Moving forward, robots will continue to assist with cast-tending tasks as well as with finishing applications, such as the deflashing of cast excess and laser ablation for cleaning parts. Suppliers will need to take stock of their current production offerings and adjust accordingly to remain relevant in an EV manufacturing world.
Supporting EV production
To successfully support many of the processes required to bring electric vehicles to the masses, an array of partnerships, methods, and technologies is being used. Joint ventures between tier one suppliers/technology companies and OEMs are forming to streamline production and reduce costs. Honda Motor Co., for example, is partnering with LG Energy Solution (LGES) to fulfill demand for Honda and Acura EV models. As a result, a dedicated battery plant is being built in southern Ohio to support Honda’s electric vehicle initiatives.
High-performance robots, along with their peripherals, are also being implemented. Whether they are being installed in new facilities or integrated into existing operations, these manufacturing workhorses tackle many challenging processes needed for electric vehicle and EV battery production. From automated assembly and dispensing to laser welding, screw driving, and more, versatile and efficient robots are ideal for completing many of the core tasks required to facilitate fluid battery module assembly. Newer processes for friction stir welding of dissimilar materials are also being conducted by robotics. Other manipulators for moving vehicle chassis, inspecting weld seams, painting car frames, and more are also helping in this space.
This diversification will go a long way to expand electric vehicle use, positioning manufacturers for long-term success.
Moving manufacturing forward
As the demand for electric vehicles rises, the automotive industry will continue to adjust and undergo transformation. Tier manufacturers and OEMs alike will need to evaluate current product inventory and subsequent processes, determining what is relevant and profitable to maintain moving forward. Research and development initiatives will play into this, helping companies improve lightweight materials, battery capabilities, drivetrain performance, and more. This diversification will go a long way to expand electric vehicle use and position manufacturers for long-term success.
If retooling an existing manufacturing facility or building a completely new one is on your company radar, visit Yaskawa’s robotic experts to discover how high-performance robots can optimize your operations, boosting throughput and quality while differentiating your company from the competition.
Published May 20, 2024, on Yaskawa’s Y-Blog.
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