Great Wall GWM Battery Frame Project

In August 2024, ASD entered into a cooperation with Great Wall Motors (GWM). Focusing on the production needs of core components for new energy vehicle battery frames, it provides full-process tooling support and inspection services covering "machining - welding - testing". With its efficient collaboration capabilities, the project was delivered in only 65 days, accurately matching the progress of the OEM's production line, laying a solid foundation for the dimensional accuracy and structural stability of the battery frame, and helping the implementation of new energy vehicle safety standards.

Figure-1	Figure-2	Figure 3	Figure-4	Figure-5

The core tooling system for this collaboration is custom-designed for the critical stages of battery frame production, ensuring high precision and excellent adaptability to meet process requirements—details are as follows:

I. Processing Stage: Controlling Precision at the Source

NC Machining Jigs and Fixtures: Provide positioning and support for CNC machining of battery frame blanks, featuring a multi-point datum-based positioning design.

Precision Metric: Repeatability positioning error ≤ 0.03 mm, ensuring dimensional consistency in processes such as milling and drilling—allowing us to control accuracy right from the machining stage. (As shown in Figure-1)

II. Welding Process: Ensuring Weld Quality and Compatibility

1. Friction Stir Welding Jig & Fixture: Specifically designed for the friction stir welding process of lightweight materials such as aluminum alloys.

Core Advantage: Integrates constant-temperature clamping with pressure-adaptive adjustment, effectively preventing welding deformation while ensuring weld strength and sealing integrity—perfectly aligning with the quality standards for lightweight component welding. (As shown in Figure-2.)

2. Outer Frame TIG Welding Fixture: Features a modular clamping structure, allowing flexible adaptation to the welding and assembly needs of battery frame outer frames in various specifications.

Precision Control: During the welding process, workpiece displacement is kept ≤0.02mm, ensuring precise control of the outer frame’s contour and guaranteeing that the joint accuracy meets the required standards (as shown in Figure-3).

3. Sleeve Welding Jig: Specifically designed for welding sleeve-type connectors used in battery frames, ensuring precise alignment of the sleeve relative to the main body.

Assembly Assurance: After welding, the coaxiality error is ≤0.05mm, meeting the subsequent assembly tolerance requirements and ensuring stable component connections.

4. Air-tightness Testing Fixture: Utilizes multi-channel air pressure detection technology, with test pressures ranging from 0.1 to 0.5 MPa.

Security Assurance: Leak detection accuracy reaches up to ≤1 × 10⁻⁵ Pa·m³/s, enabling efficient verification of the sealing performance after battery frame welding—and fundamentally eliminating the risk of electrolyte leakage. (As shown in Figure-4)

 III. Inspection Process: Efficient Verification of Finished Product Quality

Detection Scope: Achieve full-size inspection of the finished battery frame, covering more than 20 critical inspection items such as profile tolerance, hole position accuracy, and surface deviation. (As shown in Figure-5)

Efficiency Advantage: Equipped with quick-connect inspection pins and dial indicators, a single operator can complete all necessary inspections in as little as 8 minutes, significantly boosting both efficiency and accuracy.

This collaboration not only highlights ASD's strong capabilities but also lays the foundation for collaborative growth with leading automotive OEMs. ASD will continue to provide precise, high-efficiency solutions to the high-quality development of the new-energy vehicle industry chain.