At the heart of the electro-hybrid vehicle is a lithium ion battery consisting of 288 battery cells. The cells are enclosed in 135 plastic frames, each of which must feature maximum precision to ensure that the components cause no problems during assembly. The injection molds for the plastic frames were inspected with ATOS Triple Scan during prototype development. The GOM system supplies precise measurement results on the basis of full three-dimensional data. These analyses made it possible to optimize the prototypes very quickly. In this way, the required precision for the plastic frames, with a tolerance of ±0.1 millimeter, was achieved on the injection molds, with far fewer correction loops needed than was previously the case. As a result, production startup times could be significantly reduced.
More information can be found in the April issue of Composites Technology magazine at http://www.compositesworld.com/articles/chevy-volt-battery-pack-rugged-but-precise