According to the International Energy Agency (IEA), global sales of electric vehicles in 2022 exceeded 10 million units, representing about 15% of the global automobile market. In this transition towards electrification of transport, hybrid vehicles, which combine an internal combustion engine (ICE) and an electric motor, are also an integral part of the change, leading to inevitable transformations in many processes of the motor industry.
Today we’d like to show you the key differences between ICE, electric and hybrid vehicles from ARITEX’s perspective, to give you an idea of how the industry is adapting and evolving in its efforts to respond to new technological needs.
Table of Contents
ICE vehicles: Total optimisation
Thanks to our experience in integrating different types of technology, we know that the internal combustion engine dictates to a great extent the structure of a traditional vehicle. This component is generally placed at the front end of the vehicle and has been optimised over many decades to provide the best performance with the lowest consumption and emissions. These developments have been combined with revised designs of the platform that incorporate innovative materials and traditional welding techniques in a constant search for the perfect balance between low weight and sturdiness. The outcome is the robust and familiar designs that we all know.
However, the sector is now facing a collective challenge: how to seek and find greater efficiency and reduce the carbon footprint in each new ICE model. Innovation in this area involves the ability to run exhaustive profitability tests and assessments before implementing any changes in the assembly process.
Electric vehicles: Innovation in weight reduction
Electric vehicles emit zero levels of exhaust gases, and are a silent and smooth way to travel, which makes them an excellent option for anyone who doesn’t travel long distances. In cases like these, the team of engineers at ARITEX works on projects where the battery is the central element, since it takes up a large part of the lower area of the chassis on an electric vehicle, from the front seats to the boot. This factor forces engineers to work on a complete structural reworking process for a balanced weight/volume distribution.
To compensate for the additional weight, manufacturers have resorted to using materials such as aluminium and Usibor® steel for hot stamping the bodywork, which helps to reduce the number of parts and the vehicle’s overall weight. At the same time, safety continues to be paramount, so the most critical areas —such as the sides, front and parts that hold important elements of the structure (battery and motor)— are made with highly resistant materials that provide additional strength and lightness.
Thanks to the use of new materials, joining techniques have also evolved. Riveting, clinching and screwing are now more common than traditional welding, due to its low efficiency levels. Not only do they consume fewer resources, they also facilitate bodywork joining processes and make the end product more flexible.
Hybrid vehicles: Adapted techniques
Hybrids offer some degree of equilibrium between electric power and the efficiency of an ICE. They are ideal for people who also want flexibility for long road trips because they combine the best of both worlds: internal combustion engines and electric batteries.
The hybrid consists of a platform that more closely resembles an ICE vehicle, but with a few modifications to house the extra battery, which generally means less space for the cabin and boot. Despite all these changes, many of our manufacturing and assembly processes remain the same. With a few adaptations, our devices can integrate the electrical components for hybrids, which streamlines the transition for manufacturers and enables users to access this technology without any major changes to the design and functions of their vehicle.
The industrialisation process
Over decades, ARITEX has participated in evolving vehicle manufacturing. Thanks to our experience we know how to adapt and evolve in every process of change. The manufacturing cycle times of the past were longer and there were fewer automated processes. Nowadays, automated welding and assembly processes are present in almost 95 % of manufacturing lines, and that’s a factor that adds quality, efficiency and speed in every phase of the process.
Tireless and precise, industrial robots take on the heaviest and most delicate tasks in bodywork construction. At the same time, AMRs (autonomous mobile robots) safely navigate around the plant, efficiently transporting materials and parts. Collaborative robots are less common because they can carry less weight, but they are sometimes used for simple, repetitive assembly work, such as labelling and handling small electric parts.
Every vehicle undergoes a rigorous process, from a well-thought-out design to the final tests to ensure that it meets the most demanding quality standards. If you’d like to know more about the automobile industry integration process, then please do carry on reading this article , where we’ll tell you more about it.
Thanks to a solid track record in project management and a unique capacity to adapt to the specific standards of each and every customer in mechanical and electrical engineering, ARITEX provides complete, tailor-made solutions that ensure top quality and efficiency in vehicle manufacturing processes. Contact us. Tell us what your project is all about and find out how we can help you.
