Market Segment:
Railway Industry
Our partner is a manufacturer of advanced energy storage systems used in road, rail, and marine transportation. Addit is responsible for a project involving the production of aluminum battery enclosure systems designed to protect battery modules against environmental influences while ensuring high structural strength and leak tightness throughout many years of operation.
The key challenge of the project was minimizing welding distortion, ensuring the leak tightness of numerous riveted joints (approximately 200 per enclosure), and developing a powder coating process for assemblies incorporating components with varying material thicknesses. Addit developed dedicated manufacturing solutions including custom assembly fixtures, optimized assembly processes, sealing technologies, and comprehensive quality assurance procedures, including IP67 leak testing.
Another important aspect of the cooperation was conducting manufacturing trials and recommending design improvements to increase product reliability. The solutions developed by Addit were implemented by the customer, contributing to improved leak tightness and long-term structural durability. Leveraging its expertise in aluminum welding, mechanical assembly, powder coating, and leak-tightness process validation, Addit established a scalable manufacturing process capable of maintaining consistent quality as production volumes increased.
Scope of the Project:
- analysis of technical, quality, and operational requirements for battery system enclosures
- development of welding technologies and manufacturing solutions ensuring the geometric stability of the structures
- implementation of assembly and sealing processes using riveted and bolted joints
- selection and validation of assembly components, along with preparation of engineering recommendations for design improvements
- development of a powder coating process for enclosures incorporating components with varying material thicknesses
- implementation of dedicated surface preparation processes and protection of functional areas
- dimensional inspection and in-process quality control at critical stages of production
- execution of IP67 leak-tightness testing using dedicated measurement systems
- optimization of production organization and internal logistics in response to increasing production volumes
