Aumann Espelkamp GmbH

Publication on Coil Winding Technology: Also available in English

It compiles the enormous painstaking work of developers of Aumann GmbH from Espelkamp and Prof. Dr.-Ing. Jürgen Fleischer from the Karlsruher Institut für Technologie (KIT), for the first time illuminating all the important aspects of coiling technology. "We not only describe the machine processes, but for the first time include manually fed-in winding for electrical machine construction with all their work steps," says Dipl.-Ing. Jürgen Hagedorn, head of process development at Aumann. All in all, the book surely contains about 70 years' worth of know-how.

Aumann and KIT want to close knowledge gaps in the area of coiling technology among companies with their book. It is targeted at engineers who work in design of inductive product and production technology, in development and in the environment of production technology for motors. Employees in procurement, logistics for indicative production technology and, not least, plant operators of winding machines, are to profit from the knowledge summarised in this manual. "All readers, with and without know-how in coiling technology, profit from this book in particular when introducing new products," adds Hagedorn. "Ideally, product quality will increase while the development time for the usually highly complex electromagnetic assemblies reduces. The book's contents also permit successful introduction of the industrialisation process in new products."

The authors illustrate the complex contents of the 309-page-long book not only with many informative images, but also using integrated QR-codes that enable users to watch explanatory YouTube videos on individual processes on their Smartphones or tablets.

Handbook of Coil Winding (Englisch)

Technologies for efficient electrical wound products and their automated production
Jürgen Hagedorn, Florian Sell-Le Blanc, Jürgen Fleischer
Springer Vieweg, April 2017
ISBN 978-3-662-54401-3 (Hardcover: 106,99 €)
ISBN 978-3-662-54402-0 (eBook: 83,29 €)

http://www.springer.com/de/book/9783662544013#aboutBook

https://www.amazon.de/Electrification-Energy-Efficiency-Jurgen-Hagedorn/dp/3662544016

Baoying County Jinggong Insulation Material Co. Ltd.
宝应县精工绝缘材料有限公司

extra high thickness and over width polyimide film

Thickness 0.025-0.250mm, width 10-1300mm, total 10 production lines, anual output 1000T.

bdtronic Suzhou Co. Ltd.
比德利工业设备(苏州)有限公司

Audi orders bdtronic impregnation machines for e-motor production

Audi will install e-motor manufacturing equipment from bdtronic, a German mechanical engineering company, for its Premium Platform Electric (PPE) architecture in the coming years.

bdtronic manufacturers impregnation equipment, which closes and seals the cavities in windings and coils within hybrid and electric motors to provide better insulation and vibration resistance.

Bdtronic CEO Patrick Vandenrhijn said, “bdtronic has delivered and installed several high-volume machines at German Tier 1 automotive suppliers and several low-volume impregnation machines to German OEMs. We are proud that Audi has chosen us to deliver the first high-volume production machine for impregnating e-motors.”

BROCKHAUS MEASUREMENTS

BROCKHAUS presents more Automatic Testers

Besides the advancement of the established and proven products BROCKHAUS presents at the CWIEME Shanghai 2020 the new impressive, fully-automatic robot-supported SST analyse gauge for the autonomous measurement of strip sheets in various sizes acc. to IEC 60404.

More information at: https://youtu.be/LWrirzL5UXc

BROCKHAUS MEASUREMENTS

NEW: BROCKHAUS Academy

Professional training of customer staff at the BROCKHAUS Academy in Luedenscheid, Germany
- Training of operators in the use of BROCKHAUS instruments
- Support in self-maintenance works of BROCKHAUS testers
- General update of knowledge in the field of magnetic measurements
- View on future developments of hard- and soft magnetic materials
- Consulting:
- Assistance in implementation of measuring equipment
- Improvement of existing Quality Control
- Guidance in optimizing manufacturing process

BROCKHAUS MEASUREMENTS

NEW: BROCKHAUS Automatic SST 500x500 incl. Franklin Tester

Besides the advancement of the established and proven products BROCKHAUS presents at the CWIEME Shanghai 2019 the new, impressive fully automatic measuring system Single Sheet Tester SST 500x500 with integrated Franklin Tester.

More information at: https://www.youtube.com/watch?v=phpGhXoTsJ0

BTSR International S.p.A.

High Tech Revolution in Wire Feeding Tension Technology

CWF2000 is an innovative solution drastically overcoming the state-of-art of wire feeding technology and destined to dramatically impact the coil winding sector.

Changzhou CONOVO Numerical Control Technology Co., Ltd.
常州科乐为数控科技有限公司

Strengthen the independent innovation of Changzhou's leading industry and move towards "elite and special"

In Changzhou Kele Numerical Control Technology Co., Ltd. located in Wujin national high tech Zone, the precision laser cutting machine independently developed by the enterprise has been tested and the moving accuracy has successfully reached the micron level! In order to achieve this "qualitative leap", the company has innovated and developed carbon fiber mobile beam after five years, and independently developed the matching CNC system.

Changzhou CONOVO Numerical Control Technology Co., Ltd.
常州科乐为数控科技有限公司

Strengthen the independent innovation of Changzhou's leading industry and move towards "elite and special"

In Changzhou Kele Numerical Control Technology Co., Ltd. located in Wujin national high tech Zone, the precision laser cutting machine independently developed by the enterprise has been tested and the moving accuracy has successfully reached the micron level! In order to achieve this "qualitative leap", the company has innovated and developed carbon fiber mobile beam after five years, and independently developed the matching CNC system.

Chongqing Sinstar Packaging Machinery Co. Ltd.
重庆鑫仕达包装设备有限公司

Sinstar Solventless Laminators Are Easy

3.Sinstar Solventless Laminators Are Easy To Operate And We Produce 200 Units A Year

EFD Induction (Shanghai) Co. Ltd
易孚迪感应设备(上海)有限公司

Sinac: Stationary induction heating systems

Sinac universial heat generators are the most advanced and reliable induction heating systems on the market. The Sinac is ideal for a wide range of applications and is suitable for heating all kinds of electrical conductive materials.
Sinac is EFD Induction’s range of complete stationary heating systems. Each Sinac includes a frequency converter, capacitors and, where necessary, a matching unit. All Sinac coils, the components that actually deliver heat to workpieces, are custom-designed to best suit your specific applications and conditions.

EMAG eldec Induction GmbH

UNI HEAT from EMAG eldec: Induction heating system scores points in motor production at Elektror

Many industrial production processes wouldn’t be possible without fans—they play a decisive role in the drying, suction or cooling of materials. Often the stability and efficiency of the entire production process may even be dependent on the fans used. The challenging task for Elektror airsystems becomes clearer against this backdrop: The company is one of the international leaders in the production of industrial fans and side channel compressors. Elektror has been relying on UNI HEAT from EMAG eldec since mid-2018 for the production of the electric motors used in its fans: The system ensures quick and precise induction heating of the empty stator housing before the joining process with the motor winding. The process reliability and flexibility of the entire sequence are essential for the rapid “one-piece-flow” at Elektror.
Air is an indispensable working medium in industrial production: It is used, for example, to extract excess humidity or dust, cool down heated materials, remove occurring gases and vapors or transport solids in an air flow. That means fans not only constitute the centerpiece of the corresponding ventilation system, but they are also exposed to extreme pressures and are relied on for decades —a set of challenges that Elektror airsystems has been facing for many years. The company headquartered in Ostfildern, Germany, and with two production sites in Waghäusel (Germany) and Chorzów (Poland), produces about 60,000 industrial fans and side channel compressors per year. These are often customized solutions that stand out, for example, because of a precise pressure level, resistant materials or a particularly low-vibration design. In the end, there are countless customization options available when designing a fan—and that obviously also applies to the devices’ electric drives. That is why Elektror produces different size motors and performance levels. Its components are configured to order and mounted within the scope of a lean process. In doing so, the ventilation specialists place the highest importance on process reliability. Fault tolerance is always set to “zero.”

Induction Heating at the Core

In this process, thermal joining of the empty stator housing and motor winding is one of the core processes: The housing is heated to a temperature of 280 to 300 degrees Celsius (536 – 572 degrees Fahrenheit) using an induction heating system. This causes it to expand allowing the motor winding to be inserted by hand. As it cools down, the housing contracts again and establishes a form-fitting and solid bond with the winding. In 2018, the specialists at Elektror decided it was time to replace the aging heating system. How did this come about? “One of our main goals in making the investment decision was to increase process reliability around induction heating. For instance, the old system did not display the actual processing temperature that the component had reached.

EMAG eldec Induction GmbH

Induction heating by eldec: Perfect machining temperatures guaranteed for welding

Welding processes are indispensable for the production of many components in car manufacturing. The procedure is becoming increasingly important, e.g. as many screws can be replaced with welded joints on automotive gearwheels. The weight and the material costs of the component are reduced as a result. Pre-heating plays an important role in many of these welding processes. It prevents the unwanted heating of the material structure in the heat-affected zone, the area directly surrounding the weld. That effectively prevents the risk of the formation of cracks in the component after welding to a large extent. However, the processing speed in modern automotive production represents a special challenge for heating processes: During an automated process, the component must reach a precisely defined temperature within only a few seconds. Induction heating by eldec is ideally suited for precisely this requirement: The EMAG company develops comprehensive solutions relating to the innovative procedure. The corresponding generators and inductors are tailored precisely to the component. Tests on the component provide an important basis. The result is a robust and energy-efficient solution that can easily be integrated into the production line.
Producing high quantities within seconds and without any processing errors – the central requirements in car manufacturing are an extreme challenge in particular for the welding of mass-produced components. To be able to ensure the required process reliability and efficiency, the procedure is integrated into an overall process that frequently ranges from inspection and washing processes to brush processing and the ultrasonic inspection of the weld. Immediately before the actual welding process, the precise heating of the component plays a decisive role, as Dr. Dirk Schlesselmann, Deputy Head of Application Technology Research and Development at eldec, explains. “The gearwheel or the piston must be heated precisely and at high speed to the required machining temperature of about 160 to 180 degrees Celsius. However, doing so must not cause any overheating of the component, which would result in the loss of hardness, oxidation or unacceptable deformation. In these conditions, induction heating is the ideal method, as it can be applied quickly and precisely and can be exactly dosed.”


Maintenance-free and efficient technology

The specialists at eldec have acquired exceptional expertise relating to induction heating processes integrated in higher-level welding systems for many decades now. At the location in Dornstetten, both the required generators and also the inductors are produced, using efficient manufacturing processes. The generators provide the benefit of very advanced power electronics and control technology. That makes it easy to integrate them in machines or configure them precisely according to requirements.

EMAG eldec Induction GmbH

Inductors from eldec: custom manufacturing for perfect induction heating

Induction heating is a growth sector, and for good reasons. The technique is energy efficient, reliable, reproducible, very fast and its range of possible applications is almost unlimited. For example, induction can be used on parts to heat, join, braze, harden, or even melt them. A critical component in these processes is the inductor. Its design is crucial in determining how precisely a part is heated. Complex manufacturing processes are therefore used to produce this central tool with precision to a tenth of a millimeter—a task perfectly suited to the experts at eldec, with facilities in Auburn Hills, MI USA and in Dornstetten, Germany. The technicians at these EMAG subsidiary have a thorough understanding of the different applications of induction heating. For more than 30 years, they have been developing inductors to match, which are adapted to the geometry of the workpiece with painstaking dimensional accuracy.
The crucial quality in induction heating is best summarized by the word “precision.” The technology is used anywhere where a lot of energy or heat needs to be applied to a workpiece in a very short time. Temperature accuracy plays an important role here and is often process critical – and precise heating is only possible with the right mix of inductor geometry, frequency, power, and magnetic field characteristics. Furthermore, the application of energy through induction ensures fast production processes, minimal workpiece distortion, and economical energy consumption.

The process relies both on the generator used (as the power source) and, above all, on the inductor, since the form of this tool is crucial in determining which areas of the workpiece are heated. Consequently, it should not be surprising that the inductors used are as many and varied as the corresponding parts or components. For example, eldec produces ring inductors and shaped inductors that enclose the part being heated with millimeter precision. Rod inductors sit inside the part during the process, heating the metal from the inside out. Flat inductors are also frequently used, for example, in induction brazing. They heat large areas of the part surface evenly and simultaneously.

Experience is key

“In total, we produce up to 1,000 inductors every year – and the numbers are rising,” said Stefan Tzschupke, Head of Business Development Generators at eldec. “The crucial quality that many customers put their trust in is the experience of our fitters and engineers. Inductor manufacture is a demanding process that can't be automated because it depends on so many highly precise details. When you're brazing or assembling the inductor, every move has to be right.”

EMAG eldec Induction GmbH

eldec technology in the machinery industry: Standardized high-performance generators for excellent mechanical engineering solutions

Which behavior patterns are crucial to the success of the German machinery sector? Two years ago, the study "The future of German mechanical engineering" by the VDMA and McKinsey consultants provided a wide variety of answers to this question. More than 70 percent of interviewed companies pointed to the development of customer-specific systems and integration solutions as a primary factor to success —a field in which EMAG Automation has been active for many years. The company has been developing comprehensive, perfectly adapted production solutions for the automotive industry that focus, on laser welding and thermal joining technologies, among other things. Frequently included as part of the package are eldec generators, which are used as energy sources for induction heating, a critical subprocess in joining and laser welding. The reliability and performance of these generators plays an important part in the success of EMAG Automation. The eldec product range is another major factor: For each configuration, there is a matching generator—a key prerequisite for increasingly important customer-specific solutions.

Gears, differential cases, camshafts and similar engine components are rarely produced with standard mechanical engineering solutions anymore. On the contrary: The degree of customization in mechanical engineering is increasing rapidly. Customers demand highly specialized, comprehensive production solutions that should ideally be able to process a task in a "one-piece flow". All process steps, from cleaning the initial components to checking the final product, need to be integrated and adapted to the specific requirements of the component. This task calls for mechanical engineering specialists with profound knowledge and extensive experience regarding each component. With this in mind, the positioning of EMAG Automation makes even more sense: The company specializes, among other areas, in the laser machining of key transmission components and offers its customers comprehensive services in project planning and execution. The resulting production solutions guarantee huge increases in productivity. Take gears, for example: Through the automated EMAG ELC systems, they can be machined in ten seconds or less. The machine is loaded automatically, and the components are press-fitted, preheated by induction to approx. 170 °C, and welded by laser. Inductive preheating ensures that even critical materials with increased carbon equivalent or components with unfavorable geometries can be welded in a controlled manner, without any cracks. The eldec generator used in the process is crucial for creating a precise and reproducible heating. On one hand, it ensures that the required preheating temperature is reached. On the other, it prevents overheating that would lead to unacceptable changes in microstructure.

EMAG eldec Induction GmbH

PICO series by eldec: Mobile induction heating with maximum efficiency

The applications for induction heating are extensive. They extend from the automotive industry and mechanical engineering to the energy industry and electrical engineering. The experts at eldec based in Dornstetten near Freudenstadt know these applications very well. For over 30 years, the company has been developing the energy sources for them.

Low-cost technology

eldec can now provide its customers with a new solution in the form of the PICO series. This compact device is based on time-tested technology, but the configuration of central elements concentrates on the essentials. This ensures a reduction in costs for the design and ultimately in the purchase price paid by the customer. “Our aim was to develop a standardized, low-cost energy source which covers almost every field of application,” explains Stefan Tzschupke, Head of Business Development Generators at eldec.

From power plant to automotive engineering

There are three sizes available: PICO-S, PICO-M and PICO-L. These can be configured as medium frequency or high frequency energy sources from 5 to 150 kW, depending on the model. They feature eldec’s own control unit, time-tested inverter technology and an intuitive control concept. The device may be used during inspection work in a power plant, for example, to heat so-called expansion screws. Another typical application is heating components before a joining process. The PICO series is also used for standard applications such as induction brazing.

Major market opportunities

“PICO is a low-cost, standardized series with a wide range of applications,” explains Tzschupke. “With this in mind, we believe that there are major selling opportunities in Asian markets, for example, in which full functionality, high product quality and low costs play central roles.”