In order to improve quality and performance of battery material, and address the battery safety issue, the contents of nickel, cobalt and manganese elements in the cathode materials of ternary lithium batteries are accurately determined by Inductively Coupled Plasma-Optical Emission Spectroscopy (ICP-OES), and the uncertainty in the measurement process is systematically evaluated according to the standard of JJF 1059.1—2012 “Evaluation and Representation of Measurement Uncertainty”. The uncertainty factors that may be introduced in each part of the test are deeply analyzed, and these uncertainties are carefully quantified and calculated. When the nickel content of the sample is 5.521 μg/mL, the extended uncertainty is U₉₅(Ni)=0.013 1 mg/kg. When the content of cobalt is 3.566 μg/mL, the extended uncertainty is U₉₅(Co)=0.011 8 mg/kg; when the manganese content is 2.102 μg/mL, the extended uncertainty is U₉₅(Mn)=0.013 1 mg/kg. Finally, the synthetic uncertainty of nickel is u(Ni)=0.006 6 mg/kg, the extended uncertainty of cobalt is u(Co)=0.005 9 mg/kg, and the extended uncertainty of manganese is u(Mn)=0.006 5 mg/kg.

In the lithium-ion battery ternary anode materials, trace elements affect the battery performance directly, in this study, an analytical method for simultaneous determination of 19 trace elements including Nb, B, Zr, Sr, Ta, Ti, Y, La, Ga, Cu, Fe, K, Mg, P, Na, Al, Cr, Mo and Zn in ternary anode materials of lithium ion batteries is established by inductively coupled plasma emission spectrometry. The influence of different solvents on the determination of trace elements in ternary anode materials is investigated, and the best sample solvent is determined. The results show that the method is simple, rapid, and has good repeatability and reliability. The relative standard deviation of each element is 0.58%~3.56%, and the recovery is 91.81%~104.91%, which can fully meet the needs of trace element content analysis of ternary cathode materials.

To address the safety concerns of Proton Exchange Membrane Fuel Cell Electric Vehicles (PEMFCEV), this paper uses the fault tree method to explore the factors affecting the safety of PEMFCEV, analyzes the potential safety hazards of proton exchange membrane fuel cell systems, power batteries and high-voltage electrical circuits, and elaborates the current domestic and foreign PEMFCEV manufacturers’ safety prevention and control strategies adopted for hydrogen leakage, power battery, and electrical safety. The results show that the current safety measures for PEMFCEV can prevent and control foreseeable safety risks.

For the issue of PMMA toughened material which easily produces mold fouling and affects the manufacturing of automotive lighting, this paper proposes a mold fouling collection device which can be used to observe the precipitation of the mold fouling at different shear rates and examine composition of mold fouling by the method of Py-GCMS. In addition, 2 toughened PMMA materials are selected to study the influence of the material characteristics on the mold fouling by differential scanning calorimetry and thermogravimetric analysis. The results show that from a technological point of view the higher the shear rate due to shear heating, the higher the temperature, the more the mold fouling precipitates are produced; from the perspective of the material formulation, the lower the glass transition temperature, the lower the temperature rise under the same shear, the less the mold fouling is produced.

The method of laser offset is used to simulate the deviation of edge trimming precision of aluminum alloy door parts. Taking the laser focus on the lap joint edge as a reference, the effect of the different offset distance, namely trimming deviation of parts on weld forming and properties is investigated. The results show that the weld seam surface forming and cross section morphology change with different trimming deviations. In term of weld seam forming, when the trimming deviation of the part gradually increases from -1.0 mm to +1.0 mm (the direction in which the trimming of the part is away from the laser spot and exposes the lower plate of the lap joint to the laser is defined as negative, and the opposite direction is defined as positive), the surface of the weld seam gradually becomes full. In term of weld seam mechanical properties, when the trimming deviation of the part is within the range of -0.5 mm to +1.0 mm, the change of the trimming deviation has little effect on the mechanical properties of the weld seam, and when the trimming deviation is -1.0 mm, the tensile strength of the weld joint is significantly reduced. Therefore, in order to ensure the forming and mechanical properties of the welding seam on the aluminum alloy door, the trimming deviation of parts should be ensured in the range of -0.5 mm to +1.0 mm during the trial production process.

Regarding the issue of the assembly torque of the aluminum alloy bushing of the subframe and the connecting bolts to the body of a certain model exceeding the upper limit of the monitoring window and triggering an alarm, through the analysis of the bolt assembly curve, it is found that the reason for alarm is that when the assembly torque reaches the upper limit of the monitoring window, the bolt tightening has not reached the process angle yet (this position is assembled by using the torque angle method). The comparison results between the bolt states of normal assembly and alarm show that the anti-slip teeth under the bolt head of assembly alarm is embedded in the gasket, while the anti-slip teeth of the gasket of the normal assembly bolt is embedded in the aluminum alloy bushing. The anti-slip teeth embedded in the gasket under the bolt head of the assembly alarm will drive the gasket to rotate, resulting in an increase in the friction diameter, friction coefficient of the bolt head, and assembly torque, thereby causing the assembly curve alarm. The embedding of anti-slip teeth under the bolt head into the gasket is due to insufficient heat treatment of the gasket, resulting in a softer hardness that is lower than the design required value.

With the aluminum bracket of a new energy vehicle power battery as the research object, the level set method is employed to perform topological optimization on the power battery bracket. During the optimization process, factors such as structural stiffness, strength, fatigue, and dynamic safety are comprehensively considered. The optimization results are interpreted and the structure is reshaped to obtain a new structure that meets the requirements. The reshaped structure undergoes sensitivity analysis to identify sections requiring optimization. Through topology optimization, a reasonable cross-sectional shape is obtained, and the optimized structure is verified to ensure performance enhancement. Upon comparison, the optimized power battery bracket exhibits a 5.9 Hz increase in first-order modal compared to the original structure, with an overall stiffness improvement of 18.2%. The results for stiffness, strength, and random vibration are superior to the original structure. Fatigue analysis indicates that the damage to the new structure is less than 1, indicating its superiority over the original structure. Additionally, the weight of the optimized battery bracket is reduced from 209 kg to 180 kg, representing a weight reduction ratio of 13.8%.

Through-type tail lamp of a vehicle type cracks and fails during road test and it is confirmed by analysis of the cracking position that the failure is a kind of interface fatigue cracking. To address this issue, the paper confirms that mismatch between thermal expansion coefficient of Heterotropic material and mechanical properties is the cause of failure cracking. Stress distribution of lampshade is calculated by CAE software combined with sun exposure test, which shows that the stress distribution location is consistent with physical lampshade cracking. In combination of the evaluation of stress result by means of S-N curve, it rationally explains the seasonal pattern of cracking. This method is used to evaluate through-type tail lamp with different materials, colors and structures, the results shows that the highest risk of cracking appears in through-type tail lamp made from black styrene, ASA and transparent Polymethyl Methacrylate (PMMA), which is consistent with the law of after-sales statistics data.

The inner-dash sound insulation pad is an important part of the automobile firewall assembly. This paper studies the influence of different sound insulation pad materials, coverage rate, thickness distribution of soft layer and installation process characteristics of accessories on the sound insulation performance of the firewall assembly. The sound insulation performance of the firewall assembly of a vehicle model is optimized and improved through selecting appropriate material composition and soft layer thickness, improving the coverage rate of the sound insulation pad, and reducing the leakage amount.

Aiming to three cases of premature failure of steel wheels during bending fatigue and radial fatigue tests, this paper analyzes the influence of materials processing technology on wheel fatigue performance using fracture scanning, energy spectrum surface scanning, microstructure, and low magnification experiments. The shows that the aggregation of small-sized inclusions in materials, improper parameters in the synthesis welding of wheel rims and spokes, and incorrect parameters for flash welding of wheel rims all lead to the weakening of wheel fatigue performance.

To address the issues of long construction cycles and outdated, complicated solutions in traditional ANDON information display systems, this paper proposes a design approach that emphasizes lightweightness, low-code development, ease of operation, and rapid deployment. Starting from these principles, this paper outlines the functional requirements and presents a design scheme for information display, covering both hardware and software components.Based on this scheme, an integrated information display system based on Android industrial hosts is designed. This system incorporates features such as remote management and control of information boards, real-time data collection and display, design and management of board display modes, data resource management, notification delivery, and broadcast control. These features are achieved through pre-installed apps on the hosts, drag-and-drop interface development, encapsulation of dedicated functions, low-code design, and remote deployment monitoring.

Based on the experience of commissioning automated assembly technology for multiple models in a front-wheel drive vehicle project, the paper summarizes the general commissioning processes and methods related to Best-fit technology, its input-output advantages, and quality status evaluation. This paper also emphatically introduces the practical application of this technology in the production of new vehicle models, providing forward-thinking insights and standardized approaches for BIW panel parts of new projects to ensure assembly dimensions.