AUTOMATION SOLUTIONS E-MOBILITY (HAIRPINS, BUSBARS)

Focus on e-mobility

Electric mobility is gaining more and more momentum. The business potential inherent in this electrifying technology is growing correspondingly strongly. Bihler has been involved intensively in the research and development of this new technology for several years and already offers groundbreaking automation solutions.

Automotive suppliers use them to manufacture hairpins with high productivity in large numbers of variants as well as busbars with material savings of up to 50 percent. Bihler automation solutions are also convincing in the production of battery cell and module connectors completely mounted in carrier frames, ZSB circuits for direct drives, shielding sleeves, and complete HV connectors.

Electrify the world with us.

 

NEW: Whitepaper "Electromobility" - Order free of charge

Efficient automation solutions for e-components

Hairpin windings "on the fly"

With the automated manufacturing solution for hairpin windings, Bihler introduces new perspectives for industrial production. The BM-HP 3000 servo production system with standardized machining processes combines all required process steps.

You benefit from three times higher cycle rates than with sequential systems, easy and fast variant changes “on the fly”, and consistently high production reliability.

Click here for more info about the Bihler Hairpin Machine.

 

Efficient power flow

Busbars made of copper or aluminium are decisive components of powerful battery systems and the complete power distribution in vehicles.

Depending on the component length and geometry, they are produced on the GRM-NC servo-stamping and forming machine with radial or linear forming tools. For additional value-added steps, the BIMERIC servo production and assembly system offers plenty of machining freedom.

NEW: Here you can learn more about busbar production with Bihler technology

 

Advantages Bihler Technology:

  • Flexible production with a high variant diversity
    and high productivity
  • Significant material savings up to 50%
    in radial production and up to 33% in linear production
  • Cost-efficient, standardized tools with up to 70% standard parts
  • Process lengths of over 2,000 mm can be realized on GRM-NC
  • Very short tool changeovers between 0.5 and 1.5 h
  • Constantly high process reliability and quality
    thanks to integrated monitoring stations

 

Providing the power

The battery powering an electric vehicle consists of a large number of individual cells that are connected to one another by means of a cell contact system. It is important to use a high-performance cell interconnect which minimizes power loss, ensures the best possible equalization between the cells and is also suitable for a fast, uncomplicated assembly.

In practice, the illustrated cell connectors are manufactured and mounted in the carrier frame on the BIMERIC BM 6000 servo production and assembly system.

 

Advantages of Bihler Technology:

  • All-in-one production on one single system
  • Highly precise production of interconnects
  • Assembly of interconnectors together with other connecting parts in carrier frame
  • Output: 4 completed cell holders per minute

 

Racing ahead

The heart of any electric motor is the internal conductor coil. When current passes through it, it generates magnetic fields whose force is converted into kinetic energy. Depending on its design, the coil consists of an electrical conductor with multiple windings in the form of a wire or strand. At the heart of each primary winding is a u-shaped winding element (hairpin).

The winding element shown here is used in the electric motors of e-bikes. It is manufactured on a hybrid RM 40K stamping and forming machine with NC units.


b.inside - manufacturing examples

 

Advantages of Bihler Technology:

  • High output rate with 100 parts per minute
  • All-in-one production with isolation from the copper wire, notching, bending, cutting
  • NC unit allows for easy corrections when bending the wire
  • Perfect integration of RM 40K in a higher-level production line

 

Secure shielding

Shielding sleeves are used in charging plugs. They protect conductive components or circumferencial components from electrical or magnetic fields.

The delicate shielding sleeves are manufactured on a GRM-NC servo stamping and forming machine equipped with the modular LEANTOOL linear system.


b.inside - manufacturing examples

 

Advantages of Bihler Technology:

  • Flexible and precise manufacturing of delicate components
  • High output with up to 170 parts per minute
  • Cost-effective, highly standardized tools
  • Very fast time-to-market
  • 100% reproducible variant changes in less than 30 minutes

 

For the perfect fit

In modern vehicles, vast quantities of electronics ensure the precise positioning of a wide range of different components. The motor housings are of particular importance. They must fit precisely around the internal components and must have exactly the right diameter. In this context, the construction of double-walled motor housings is particularly demanding. This form of construction increases the performance of the electric motor. At the same time, less force is required for forming and calibration.

In practice, these double-walled electric motor housings are manufactured on a GRM-NC servo stamping and forming machine.


b.inside - manufacturing examples

 

Advantages of Bihler Technology:

  • High output rate with 45 to 55 parts per minute
  • Flexible production of the different housing variants
  • Extremely short setup times and one hundred percent reproducibility

 

Important interface

ZSB circuits are used in hybrid vehicles. They are used for contacting the single-tooth stator coils in the electric motor. The coil wires are contacted at the respective stamped protrusions. The wiring is thus the interface component between the stator of the electric machine and the inverter.

The BIMERIC BM 6000 servo production and assembly system offers the perfect platform for the production of complete ZSB circuits.

 

Advantages of Bihler Technology:

  • Completely automated production on one system
  • Output: 3 to 4 ready-to-install ZSB circuits per minute
  • Fast retooling from one variant to another

 

Standardized, modular solution platforms for your e-components

Efficient assembly production

The BIMERIC servo production and assembly system is the ideal solution platform for your assembly production.

The modular system shows its benefits especially for small and medium batch sizes and if you require a large number of different versions. The intelligent VariControl control platform is the core element of the high-performance machine. It guarantees maximum process reliability and machine availability as well as extremely fast, 100 percent reproducible setup operations.

 


Depending on your task, we integrate standardized Bihler servo process modules for all manufacturing, assembly and machining tasks on the BIMERIC. With the efficient flow production from raw material to installation-ready final product, you shorten your process chain and achieve a consistently high product quality.

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Powerful servo systems

The RM-NC and GRM-NC servo stamping and forming machines guarantee the highest productivity for your manufacturing.

The compact servo machines impress with their high performance as well as with their extremely short setup times. To achieve this, the (G)RM-NC machines are equipped with an automatic positioning system for all NC units. By calling up the stored parameters in the VariControl control system, the axes can be aligned 100 percent reproducibly.

 


Hydraulic quick-clamping systems allow for a simple tool assembly in a matter of minutes. Production immediately starts with a good part. In combination with the standardized LEANTOOL tools, you benefit from up to 70 percent reduced tool costs and a very fast “time to market” for your products. The intuitive VC 1 guarantees maximum process reliability and optimum ease of operation.

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Intensive research and development

Bihler has been intensively involved in the research and development of the new technology for years.

Are you interested in our consulting services on e-mobility?

Martin Lehmann
Key Account Manager E-Mobility

Otto Bihler Maschinenfabrik
GmbH & Co. KG
Lechbrucker Str. 15
87642 Halblech

Phone: +49(0)8368/18-136
E-mail: