New Energy Vehicle Plastic Frame with Pull Rivet Screw Solution

New Energy Vehicle Plastic Frame with Pull Rivet Screw Solution

Technological innovation has not only changed the manufacturing of traditional fuel vehicles but also profoundly impacted electric vehicles. Nowadays, power batteries, as an essential component of electric cars, have been at the forefront of innovative assembly in the automobile industry.

In the field of transportation, the electrification of vehicles has gradually become a trend. By utilizing electric energy from diversified sources to replace traditional fossil energy sources, electric cars can significantly improve energy conversion efficiency but also help reduce greenhouse gas emissions, enhance air quality, and reduce noise pollution. In addition, the electrification of vehicles improves national energy security, realizes sustainable development, and meets the requirements of various policies. As one of the most innovative clusters in the automotive industry, electric vehicles also have great potential to enhance economic and industrial competitiveness.

The power battery system is complex, including a battery management system, an enclosure part, and numerous battery modules. The battery pack consists of multiple modules, each composed of various power cells connected in series and parallel. Battery management system, the battery monitoring and management system, through the collection and calculation of voltage, current temperature, and other parameters, controls the battery charging and discharging process to achieve the protection of the battery to ensure that the battery is packed every day and safe work.

The assembly of the power battery pack mainly involves the arrangement of multiple modules, fasteners, and structural connectors (waterproof sealing rivet nuts, high-strength hexagonal French nuts, carbon steel 8.8 hexagonal flange screws) and inspection of the junction box. During the assembly process, many stations are involved in safety connections, and these assembly processes are directly related to the safety of the vehicle's occupants.

1. High and low voltage connector assembly: battery pack or BMS on the distribution of a lot of high and low voltage connectors, the assembly of these interfaces are safety parts, the need for data feedback, the need for sensor-type tools; interface tightening is usually a single-handed workpiece, single-handed tools, so the best use of the gun-type tool grip tightening is the most convenient; torque range is not extensive, easy to choose a compact tool, combined with a high-strength screw nut Structural connection.

2. Installation of high-voltage wiring harness: There are total positive and negative high-voltage wiring harnesses in the battery pack that need to be connected and assembled, and the voltage of this part of the connection is up to hundreds of volts when the module is charged. Usually, the floor of the workstation is insulated to protect the workstation from high voltage. In addition, the assembly also needs to be insulated; the insulation of this part of the workstation affects the safety of the battery and the safety of the operator's life.

3. High-voltage copper bar connection and installation: A high-voltage copper bar is used to connect the conduction between modules, which has a large current and is used intensively. The assembly is complicated, as the critical structure of the battery conduction, the safety of the assembly is also crucial, and the negligence of the assembly may lead to short circuits of the battery.

4. Module installation: The battery pack consists of several battery modules; the assembly of battery modules requires moderate tightness and sufficient strength of each structural part to prevent deformation or damage due to external force inside the battery. Battery modules and several power cells combined in series and parallel, the assembly of battery modules need to be fixed in the aluminum box, generally use long bolts through the module set to the bottom of the box nut; there are also battery packs to save space, the use of double modules in the form of the module will have to install the module bracket for fixing the upper layer of the module.

5. Top cover installation: battery pack for weight reduction, usually aluminum shell. Battery pack aluminum shell cover and the lower box through dozens of bolts connected to the assembly, the number of bolts and the distribution of rules, the tightening direction is vertical down, in the assembly needs to be sequentially tightened to ensure that the upper cover of the tightening of the distribution of stress uniformity, lightweight in the selection of nylon rivets, nylon snap parts for connection locking.

Battery modules are charged and discharged in the manufacturing plant, and installing and replacing modules is generally electrically charged. Therefore, using hand-held wired tools carries the risk that the conductive metal will conduct and eventually form a loop, with the potential difference traveling through the bolt to the tightening tool, to the controller, and to the person holding the tool being connected to the loop in series. There is a high risk of this condition being fatal due to the short-term currents generated at 400 - 600V. In the assembly of battery packs, there are many assembly locations where voltages of up to several hundred volts can be present, and it is essential to insulate the nylon rivet connections when bolting on these locations.

Push-In Rivets: No installation tools are required—use your thumb to push these rivets into place from one side of the material. Pop them out with a removal tool (sold separately) to remove them. Made of nylon, rivets absorb environmental moisture, affecting dimensions and other properties.

Plastic Blind Rivets: Corrosion-resistant and nonconductive, these rivets are designed to join plastic, fiberglass, wood, and metal. They enter material when you only have access to one side. A low-profile domed head creates a finished appearance.

The combined thickness of the material must fall within the rivet's material thickness range. Shear strength is the force it takes to break a rivet from the side, and tensile strength is the pull a rivet can withstand without breaking. Joint strength is also affected by rivet spacing and hole size.

The nylon mandrel absorbs moisture, which can affect dimensions and other properties. Acetal mandrel is more moisture resistant than nylon.

A tool for plastic blind rivets (sold separately) with a nosepiece that matches the rivet's diameter is required for installation.

Reusable Push-In Rivets: A flexible shank allows these rivets to be removed and reused. The shank collapses when these rivets are pushed through a hole, then springs back completely to hold fast. Use your thumb to move into place from one side of the material. To remove them, pop them out with a removal tool.

Plastic Removable Pin-Drive Anchors for Block and Brick: These anchors are also known as drive rivets. To install, hammer the pin into the body. Pry out the pin to remove it.

With the development of lightweight automotive technology, using aluminum alloy materials in the body and more non-metallic parts, light can be achieved, thereby reducing the quality of the body to perform better energy saving and environmental protection effects. Currently, the aluminum alloy body mainly uses an aluminum alloy profile skeleton combined with the structure of the skin, in which the alloy profile connection is especially welding and riveting. Riveting relative to welding has a simple process, equipment, fixtures, and fixtures cost is low, and the body is not easy to deform in the assembly, etc.; therefore, through the riveting way to achieve the connection of aluminum alloy profiles, its application is also becoming more and more widely used. The rivet nut is used through the rivet gun to realize the riveting connection; it is suitable for square tubes, round tubes, and so on, and it is not easy to pressure the riveting operation of the occasion. Rivet nut application does not need to attack the internal threads, do not need to weld, the use of pneumatic or manual rivet gun can be a riveting, convenient and fast, the existing rivet nut in the use of the process will need to be in the surface of the plate or tube body to open the mounting holes, and then will be placed into the mounting holes of the rivet nut, the use of rivet nut head and the rod part of the deformation of the standard clamping plates or tubes on the part of the body, through the rivet gun on the part of the screw By the rivet nut head of the access into the rod part of the access cavity, the screw part of the threads and rivet nut access threads with the screw, the rivet gun from the rod part of the head to move, thus pulling the rod part of the deformation, the rod part of the deformation and the head of the rivet nut in the mounting holes on both sides of the plate or tube body to clamp, so as to realize the tube body, plate body mounting holes of the rivet nut at the (fixed), thus realizing the rivet nut fixed, in this process, due to the mounting hole of the cross-sectional area is slightly larger than the cross-sectional radius of the body part of the rivet nut rod, and thus in the installation process, if the rivet nut is not placed in the area of the axis of the mounting hole with the axis of the standard line, then the installation of the rivet nut may be tilted or easy to rivet nut in the process of the later use of the rivet nut triggered by the loosening of its own.

Aluminum Twist-Resistant Rivet Nuts: These rivet nuts are one-third the weight of steel rivet nuts and are mildly corrosion-resistant. A ribbed body holds the nut in place, so it won't turn when tightening a screw. Also known as blind inserts, they can be installed when you can access only one side of the material. Install in a drilled hole using a rivet nut tool. The tool collapses the nut, creating a backside flange that holds the nut to the material. Length is measured from under the flange. Installed length is the maximum length of the barrel when installed.

Twist-Resistant Rivet Nuts for Soft Materials: Wedges under the flange lock the nut in place in soft materials such as brass and aluminum, so it won't turn when tightening a screw. Made from aluminum, they're one-third the weight of steel and mildly corrosion-resistant. Install in a drilled hole with a hydraulic/air-powered rivet nut tool. The tool collapses the nut, creating a backside flange that holds the nut to the material. Length is measured from under the flange. Installed length is the maximum length of the barrel when installed.

Aluminum Low-Profile Rivet Nuts: These low-profile rivet nuts are one-third the weight of steel rivet nuts. They have a low profile for light-duty fastening in low-clearance applications. A cadmium or tin-zinc plating provides corrosion resistance and adds lubricity so they collapse smoothly. When installed, the threaded portion is drawn into the sleeve, creating pressure against the hole to secure the nut. The drill bit size in the table is for material with a 0.030"-0.090" thickness. These rivet nuts may be installed in thicker material but require larger holes. Install them using a hand- or power-driven rivet nut tool. Length is measured from under the flange. Installed length is the maximum length of the barrel when installed.

Aluminum Rivet Nuts: These aluminum rivet nuts are one-third the weight of steel rivet nuts and have mild corrosion resistance. Also known as blind inserts, they can be installed when you can access only one side of the material. Install in a drilled hole using a rivet nut tool. The tool collapses the nut, creating a backside flange that holds the nut to the material. Length is measured from under the flange. Installed length is the maximum length of the barrel when installed.

Flange-Sealing Rivet Nuts: The PVC foam seal under the flange keeps liquids and gasses from leaking between the nut and the surrounding material. These rivet nuts have a ribbed body to hold them in place when tightening a screw. The body is aluminum and mildly corrosion-resistant. Install in a drilled hole using a rivet nut tool. The tool collapses the nut, creating a backside flange that holds the nut to the material. Length is measured from under the flange. Installed length is the maximum length of the barrel when installed.
Please contact us if you want high-quality nylon and blind rivet nuts fasteners or technical support for structural design. Thanks.Email:adelajonly@gmail.com

Website: https://www.juxinfasteners.com