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EJOT offers quality and production advantages for electric vehicle charger manufacturers

How can EV charger manufacturers respond to increased demand without compromising other design and performance goals?

Designers and manufacturers of Electric Vehicle chargers must respond to increased demand and scale-up production as required through efficient design and assembly. But without compromising other design and performance goals, EJOT fastening solutions may be the answer. Dan Lunn, EJOT UK’s Application Engineer, explains how.

As electric vehicles (EVs) and hybrids increasingly replace internal combustion engine (ICE) vehicles, the demand for EV chargers in our homes and at commercial and public premises is set for huge growth too.

If sales predictions for EV uptake come to fruition, it is anticipated that by 2030 we will have between 8 and 11 million hybrid or electric cars on the UK’s roads. That number of vehicles will require millions of additional charging points when you consider that figures for May 2023 show that the UK has 1.28m plug-in cars registered, 780,000 of which are battery electric vehicles (BEVs) and 500,000 plug-in hybrids (PHEVs).

No surprise then that EV manufacturers are looking to innovators in fastening systems to take their production and assembly methods to the next level. In the same way that vehicle manufacturers across the globe are innovating in all areas of vehicle design by utilising advanced screws for joining lightweight plastics, EV wall charger manufacturers are moving forward with greater efficiency and continuously improved quality.

Unlocking potential

With the EJOT range of screws, optimising the assembly of wall charging units is easily achievable. The capability of our fasteners to streamline production through their versatility and provide long term cost savings, whilst also delivering higher joining performance, will help EV charger manufacturers to satisfy the growing market sustainably.

Most importantly, we understand the multiple design objectives of EV wall charger designers and manufacturers extremely well, because we serve numerous other industrial sectors with comparable challenges – sectors where assembly uses similar materials at similar volumes. This is why a solution that works for the 50 or so fastening elements used in the assembly of every EV charging station is readily available within our screw range.

We have particular expertise in reliably joining plastics, composite materials and foams, which can often facilitate a different approach to an assembly than that originally proposed. The EJOT range includes metal screws for plastics, plastic screws, friction-weld systems, plastic fasteners and removable fasteners – all of which are designed to provide high strength joints to ensure the finished product achieves the robustness and longevity sought in the design.

Evolve design and production with the EVO PT-S
One particularly suitable EJOT fastener for EV charger assembly is the EVO PT S. Such are the capabilities of this screw that it can offer huge scope for greater standardisation throughout product assembly – one screw size can be used for multiple fixing points. And it is a product with proven product performance too.

The EVO PT S screw for direct fastening in plastics provides its standardisation potential due to an insertion-depth-independent installation torque. Where normally various screw dimensions for different fastening points in the wall charging station are used, with EVO PT S only one screw size is required.

This standardisation can deliver far-reaching benefits. By reducing the number of different screws required, manufacturers of EV chargers can simplify installation, ordering and stockholding. Streamlining all these processes helps to engineer-out cost with the potential to improve productivity of the whole operation.

In addition, the EVO PT S screw is supported by the EJOT EVO CALC® prognosis program. This digital tool is available to designers to use in the development phase for advance computation of the screw joints to help save time and cost.

Early design engagement key to success
The benefits achievable through the use of EJOT products, such as the EVO PT S, are maximised through early engagement with our industrial fastening specialists based here in the UK, with additional support from colleagues throughout the EJOT Group.

It is crucially important, therefore, to talk to us at the concept stage or a planned review of an existing EV charger in order to realise the full benefits of alternative joining approaches.

What to know more? Read about the fasteners featured in this article:

  • EVO PT S - The self-tapping screw for plastics
  • EVO CALC® - Prognosis software that can accelerate R&D programmes

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An illustration of the charging process for an EV which can all be supported with EJOT fastening solutions.

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The demand for EV charging units will rocket as EV sales increase which will require higher production volumes.

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Wall charging unit design and manufcacture can benefit by utlising various EJOT fasteners.