Electric vehicles (EVs) have been around for a while. But now, due to advancements in technology and increased reliability, many big automotive companies believe that Electrical Vehicles (EV) are the future. The trend is clear for transportation to be sustainable; every vehicle should run on electricity. Today, we see more electric cars on the road, which shows that people care about their impact on the environment. By choosing EVs, industries and individuals aim to reduce their carbon footprint and make the world healthier for future generations.

Apparently, any new product development comes with various challenges, and manufacturing is one of them. Although electric vehicles have been built over the years in different industries, it always comes with new challenges due to improving technology and product maturity.

No matter how carefully you have designed the parts of the vehicle, including all minute details, you still face problems while assembling them in the factory. This is especially true when electricity is involved, as people with limited knowledge about electricity feel reluctant and unsafe assembling the parts of the vehicle.

My client, Scania CV AB, has encountered issues with the assembly of Battery Electric Vehicle (BEV) trucks, including general apprehension among assemblers working with these vehicles. In this thesis project, we are mapping the process flow from battery pack preassembly through to the completion of the truck assembly, including the integration of all electrical components and the initial startup for final checks. Our goal is to identify bottlenecks in this process and propose solutions, as well as to visualize a new sequence for safely mounting battery packs using safety-integrated devices.

Testing and results for this thesis project will be focused on validating the new process of assembling the battery packs, connections and routing of the 24 volts electric cables and turning on the master switch of truck electrical system after the continuity test with newly designed tool to ensure that there is no short-circuit in the system, which means that there are no wrong connections to avoid possible electric shock incidents.

The conclusion for thesis project is finding the efficient assembly sequence and new tools for testing the electricity continuity, before the battery packs are connected and electric vehicle master switch is turned on to ensure that there are no short circuits within the system so that these tools help assemblers feel safe in working with high voltage cables and battery packs.