Marschner, O.Pabst, C.Pasquale, P.2022-01-112022-01-112021-10-14http://hdl.handle.net/2003/40661http://dx.doi.org/10.17877/DE290R-22519Many countries strongly support electric propulsion for various fields of transportation, be it people or goods on land, at sea or in the air. Although electric drive systems appear much simpler than (internal) combustion systems, they exhibit their own challenging development tasks. This becomes obvious when an ever-increasing efficiency, performance or production rate is required, just to name a few. The new challenges can be tackled with the help of new electromagnetic manufacturing processes. High speed processes with their well-known unique capabilities offer promising approaches. However, development is required in order to deliver the required performance. High-speed forming with electromagnetic tools allows the production of sharp-edged battery housings. For body panels, sharp edges are mainly a design feature. For batteries, however, sharp edges allow for an almost ideally rectangular housing, enabling a higher energy density. Increases in the range of up to 10 % are achievable. When it comes to packaging, the liquid cooling and heating of battery packs is of equally large importance. The channels for the medium must not consume too much space. The integration of channels inside the aluminium or steel frame of the battery pack is a promising approach. Due to the high welding speeds of up to 500 mm per second at optimum conditions and at the same time the ability to weld aluminium to aluminium or even steel without any loss in strength, electromagnetic pulse welding offers a promising solution. The conduction of high electrical currents with for example the strong demand to save weight and thus use as little material as possible also requires new processes. Electromagnetic pulse welding of aluminium to aluminium and aluminium to copper is well known, investigated and already used in mass production. However, this is suitable for bus bars only. The connection of terminals to cables is mostly done by crimping. Using a pulsed force for crimping improves the compaction and thus the resistance of the joint, especially of cables with large cross sections. This allows for smaller connectors and reduced cable cross sections.enelectromagnetic pulse processescrimpingweldingelectrical mobility620670Text