By Sébastien Frasse-Sombet
Senior Global Product Manager, ARaymond

As the automotive industry continues to evolve and electric vehicles (EVs) become more mainstream, innovations are affecting all vehicle components, including the fasteners and assembly systems used.

One such system is thermal management, a critical element of an EV, with dozens of connection points in each vehicle. The EV and its battery pack must be adequately cooled to ensure safe and efficient operation. It’s essential to secure all fluid lines to avoid leakage inside a battery pack or near the vehicle’s electric components.

Autonomous driving functions are expected to increase this requirement. During autonomous driving, a vehicle’s ADAS computer is cooled by the same liquid that cools the battery. Loss of function can damage the calculator from overheating, potentially leading to an accident. As a result, OEMs are increasing demands for secure connections and product traceability.

In addition to helping automakers ensure EVs are as safe as possible, advances in fastener solutions for thermal management are also making the process of building EVs more ergonomic — allowing suppliers to tailor and customize parts for each requirement. The result is a better and safer electric vehicle for drivers.

Safety first
A key element of thermal management fluid interfaces is a reliable locking mechanism. This comes in many forms. Some quick connectors, when inserted, can provide visual, tactile, and audible confirmation — so an installer feels and hears when the connection is made.

Other options include the use of QR (quick-response) or DMC (datamatrix) codes, allowing for better traceability. QR codes are two-dimensional matrix barcodes invented in the mid-90s. They were initially created to track automotive parts during the assembly process and became widely used in consumer products in the 2000s.

DMC is also two-dimensional but square and can store a significant amount of information. For this reason, it’s becoming the preferred method of encoding data.

In either case, this data is available for review in the event of any concerns or maintenance issues with the vehicles. Such verification is critical for safety and traceability reasons, making identifying possible root causes of potential problems easier. Secured fasteners for thermal management systems and fluid line connections keep EV drivers and passengers safer, an essential goal for all automakers.

Better health
Advanced connection systems for EVs also mean improvements for the technicians building and installing these fastening solutions. This is because many connectors used on EVs have become low-push quick connectors — which means less insertion effort is required during installation.

This is important as it saves plant workers potential repetitive strain or musculoskeletal injuries from accessing the installation point continually throughout their shift.

Typically, these installation points can be challenging to access, increasing the chance of a faulty connection, which can lead to vehicle component damage or poor reliability. There’s also a significant number of connectors required in every EV.

Additionally, larger fluid lines are used, so a proper connection requires more force. When done manually, ergonomics are a concern. By simplifying the architecture of fastener installation, OEMs provide a safer workplace for employees assembling EVs while improving vehicle reliability.

Versatile designs
Automakers have specific requirements and specifications for their electric vehicle lineup. Special features and custom component designs have become essential. One such feature is lightweighting, especially for EVs where vehicle weight and range are significant.

Many custom designs are compressed in size so they fit into tight spaces. The trend toward smaller connectors allows for better space optimization and reduced weight. Part materials can be plastic or metal to serve the connection point best, whether for the battery pack or to seal in individual battery cells.

Suppliers can work with OEMs to offer environmentally friendly materials, eco-friendly designs, and a full lifecycle analysis of the parts. This allows suppliers to play an important role in helping OEMs reach their CSR goals. Custom designs further allow connections to be built for ease of assembly and serviceability, as well as with sustainability in mind. An improved sustainability model minimizes the OEM’s footprint while maximizing coolant flow.

While EVs are presenting new fastening challenges due to a focus on thermal management, the industry is rising to the challenge with products that improve vehicle safety, address ergonomic issues at the assembly level, and create customized solutions that will benefit the automakers and the environment.

Sébastien Frasse-Sombet is a Senior Global Product Manager for global automotive supplier ARaymond.