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Tolerance compensation systems for high-voltage batteries

Powerful high-voltage batteries are the heart of electric vehicles. To ensure the functional safety of the vehicle and to maintain the service life of the battery in the long term, a stress-free connection is crucial. This is where the tolerance compensation systems from WITOL come into play.

Battery connection of the high-voltage storage unit
High-voltage batteries, which are used in the electrified automotive industry, are rigid components with very high tolerances that have to be connected to the body. The high-voltage battery is a very sensitive component. Even a minimal distance between the contact surfaces can lead to unequal bending forces and stresses during assembly.

The bodywork, on the other hand, is comparatively susceptible to torsion, so considerable deformation of the bodywork and impairment of the gap dimensions and joint patterns can already occur during installation. Tension-free attachment of the battery to the vehicle underbody is therefore crucial for flawless quality.

WITOL has developed particularly robust tolerance compensation systems for the battery connection. The WITOLs are preassembled either on the battery housing or on the vehicle body. In the bolting process, the tolerances are compensated in the axial direction. By means of suitable slotted or square holes and sufficiently large screw heads, even compensation radially to the screw axis is possible.

Internal connection of the individual battery cells
The internal connection of the individual cell modules to the battery housing is also subject to tolerances. If the component is screwed together conventionally, the tolerances between the cell modules and the cooling base are usually compensated for with cost-intensive heat-conducting medium. This leads to poorer heat dissipation and higher vehicle weight. In addition, high compressive stresses can occur, which lead to deformation and insufficient thermal management of the high-voltage battery.

With the same active principle that is already used for the external connection of the high-voltage battery, WITOL tolerance compensation systems equalize the gap between the cell module and the housing flange without stress. The negative effects that arise in the conventional bolting process are thus effectively eliminated. The use of a universal screw connection also makes it possible to remove and install individual cell modules during servicing.

Further reading

Exhibitor: WITOL


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