Bolting together E-Semi Prototypes Could Cause more Harm than Good

The goal of every #electricvehicle #startups is to create a prototype, but what will this mean for the production model? It is used to test out new ideas or concepts and see how they work in practice. This is an essential step in the development process, allowing the start-up to qualify its idea. The easiest path to a prototype is to bolt most of the joints together. Teams can assemble and disassemble their prototypes in a garage or shop.

One of the main concerns with bolting is that it can lead to a loss of torque over time. This means that the screws or bolts will gradually loosen, which can lead to problems with the vehicle. It is, therefore, essential to ensure that the torque on a bolted joint is maintained.

From wheel hubs to adjustable portions of the truck, parts of the #EV #semitruck, #van, or #heavyequipment will require service in a shop. To prevent #vibration #loosening and long-term #maintenance issues, it's always best to choose a permanent joint like welding or blind rivet products. Some of these permanent solutions can be removed in a shop, making them serviceable and safe. We cover three permanent options below, with one of them being serviceable in a shop or repair facility:

1. Pros and Cons of Welding – This is the oldest permanent joint in the world, and it's used in every industry, from cell phones to trucking. Welding engineers are crucial, and experienced welders are a must, but use this option with caution because while it's easy to join two materials, it's permanent, not fixable on the line, and dangerous if not done right.

2. Riveted Joints – Structural rivets like Monobolt®, Interlock®, and Magna-lok® are used on several battery box designs for electric vehicles. These rivets have high shear and tensile strength, and they can be made water-tight in the proper application or by adding a sealant to the rivet. They require special tools and installation with space access, so ensure you understand the product before designing it.

3. What are Huck® Bolts – Huck® Fastening created a revolutionary part in the trucking, train, and bus markets many years ago. Now they and Stanley Engineered Fastening produce parts for the industries they support. The difference between this permanent option and the two above is that it can be removed easily with a collar cropping tool in your shop. You can replace the welded joints with a serviceable permanent vibration-proof joint.

Bolting together your prototype is the easiest way to create a functional concept to review, but don't ignore the need to produce that truck in volume long-term. Trucks will see a lot of miles on many different highways experiencing various levels of vibration and corrosion in their travels. If they are electric, they need to pass IP watertight test as well, so either let our teams help you navigate those challenges or reach out to someone who can. Please don't wait till it’s too late.