How Tongzheng Equipment Elevates EV Battery Tray Extrusion Quality & Output

2026-07-21 16:21:58

Bottom Line Up Front: A matched set of Single Billet Sawing and Stacking System, vibration-free Aluminum Puller, and uniform Cooling Table cuts EV battery tray scrap from 18% to under 2%, boosts line output by 32%, and delivers the ±0.1mm dimensional accuracy required by automotive OEM standards.

The global electric vehicle boom has turned aluminum battery trays into one of the fastest-growing and most technically demanding extrusion applications. These large, multi-chamber profiles carry 500–700 kg battery packs and must meet extreme standards for flatness, dimensional precision, and structural integrity. Even a faint vibration mark can create a stress concentration point; even 0.5 mm of warpage can break the sealing of the pack. For extrusion suppliers, winning an OEM contract depends not on having a big enough press, but on having auxiliary equipment that can deliver consistent, defect-free production at scale.

Single Billet Sawing and Stacking System: Precision Starts With the Billet

The Single Billet Sawing and Stacking System produces perfectly squared, burr-free billets with consistent length, eliminating the root cause of uneven heating and asymmetric metal flow that distorts battery tray geometry.

Many quality problems in battery tray production trace back to the billet preparation stage. A poorly cut billet with angled ends or surface damage heats unevenly in the billet oven, causing temperature variations that lead to inconsistent flow through the die. The result is wall thickness variation, twisting, and internal stress that only becomes visible after cooling and machining. Traditional saws with fixed feed rates also suffer from frequent jamming, which interrupts production and damages carbide blades, adding cost and unpredictability to the process.

Tongzheng’s Single Billet Sawing and Stacking System solves these issues with intelligent anti-jamming feed control that monitors cutting resistance 100 times per second and adjusts speed dynamically to match 6061-T6 and 6082-T6 alloy hardness. The oil-immersed spindle delivers rigid, vibration-free cutting, producing perfectly square end faces with mirror-smooth surfaces. The coaxial translation loading mechanism handles billets gently without impact damage, preserving surface integrity before heating. Downstream, the Full-Servo Stacking Manipulator arranges billets into precise stacks ready for automatic oven loading, creating a fully automated preparation flow that requires zero manual handling. For battery tray production, this level of billet consistency is the first and most foundational step toward meeting OEM dimensional tolerances.

Aluminum Puller: Vibration-Free Traction for Defect-Free Surfaces

The three-head Double-Rail Aluminum Puller delivers seamless, zero-impact continuous traction, completely eliminating handover vibration marks and maintaining the ±0.1 mm position accuracy required for wide battery tray profiles.

Battery tray profiles are typically 400–1200 mm wide with thin, delicate walls and complex internal rib structures. Traditional Double-Head Pullers struggle with these profiles: the abrupt impact during handover sends shockwaves through the hot aluminum, leaving periodic vibration marks on the surface and causing micro-distortion in the internal chambers. These defects are often invisible to the naked eye after extrusion, but they become glaringly obvious after CNC machining and surface treatment — and they can cause entire batches to be rejected by automotive customers.

Tongzheng’s Three-Head Aluminum Puller eliminates this problem entirely through its alternating traction design. While one head pulls the profile, the second head accelerates in parallel to match extrusion speed perfectly. At the moment the synchronous saw cuts the profile, the second head takes over with zero impact, zero speed difference, and zero vibration. The TZJX Servo System maintains traction force and position with ±0.1 mm accuracy, ensuring that even the widest tray profiles remain perfectly straight and flat throughout the pull. The result is completely mark-free surfaces and uniform wall thickness, which are critical for both structural performance and sealing reliability. For manufacturers, this means scrap rates drop from an industry average of 15–18% down to 2% or less.

Cooling Table: Uniform Cooling Preserves Dimensional Accuracy

A precision-engineered Cooling Table with balanced multi-zone airflow prevents differential contraction and warping, ensuring battery trays stay within flatness tolerances permanently, not just at the press exit.

The most insidious quality problem in battery tray production is delayed warpage. A profile may measure perfectly straight when it leaves the press, but internal stresses from uneven cooling cause it to twist or bow hours or days later — often after it has already passed inspection and been shipped to the customer. This happens because traditional cooling tables have uneven airflow distribution, with hot spots in the center and over-cooled edges. The resulting differential contraction locks internal stresses into the profile, which relax over time and cause dimensional drift.

Tongzheng’s Cooling Table solves this with a scientifically optimized air distribution system that delivers identical cooling velocity and temperature across the full width and length of the table. Multiple high-efficiency variable-speed fans are positioned and angled to eliminate hot spots, ensuring that every section of the wide battery tray profile cools at exactly the same rate. The heavy-duty, precision-aligned rollers support the profile without sagging, and the non-marking roller surfaces prevent scratches on the soft hot aluminum. The result is profiles that exit the cooling table stress-free and dimensionally stable, with flatness deviation under 0.5 mm per meter. This level of stability is essential for battery trays, where post-extrusion warpage can ruin the leak-tight seal of the battery pack and create serious safety risks.

The Integrated Advantage for EV Tier-1 Suppliers

When deployed together, the three systems create a fully controlled production flow that delivers the repeatability and traceability automotive OEMs require, enabling suppliers to qualify for multi-year high-volume contracts.

For EV component suppliers, winning business from tier-one automotive customers requires more than just good sample parts — it requires proven process capability with Cpk values above 1.33 or even 1.67. This level of consistency is impossible to achieve with manually operated, mismatched auxiliary equipment. An integrated Tongzheng line, by contrast, delivers recipe-based control, automatic data logging, and repeatable performance across every shift, every batch, and every order.

Real-world results from our EV industry customers confirm the impact: one leading battery tray manufacturer saw line output increase by 32%, scrap fall from 18% to 1.8%, and customer quality complaints drop to zero within six months of upgrading. Most importantly, they were able to qualify for three new OEM programs that would have been out of reach with their old equipment. For extrusion companies looking to capture a share of the fast-growing EV market, upgrading auxiliary equipment is the fastest and highest-ROI path to competitiveness.

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