Fans are used in a number of production processes—they play a key role, for example, in extracting gases, cooling down materials or transporting solids at the heart of ventilation systems. Elektror airsystems, headquartered in Ostfildern, Germany, and with two production sites in Waghäusel (Germany) and Chorzów (Poland), is one of the international leaders in the manufacturing of industrial fans and side channel compressors. About 60,000 devices are produced here every year. For the production of its electric motors, used in a variety of fans, the Waghäusel site has been relying on UNI HEAT from EMAG eldec since May 2018: The system ensures precise induction heating of the empty stator housing before the joining process. An interview with Roland Sand, Head of the Production team at Elektror airsystems, about choosing the right supplier, the collaboration with EMAG eldec and the meaning of process reliability follows below:
The first battery-powered electric vehicles could be seen roaming the streets as early as the 19th century, before the combustion engine was invented. The successor technology only prevailed in the 20th century, and one of the primary reasons for that was that combustion engines enabled significantly greater ranges of speeds. The basic operating principle of an electric motor hasn’t changed since the technology was invented in the 19th century: An engine consists of a moving element (the rotor), and a stationary element (the stator), which is permanently attached to the housing. When a current flows through the motor, the two elements have different magnetic fields, which repel each other – causing the rotor and the rotor shaft to move.
Welding processes in the automotive industry pose a special challenge for production planners. The process must be performed within seconds and without any negative impact on the material – anything but a trivial requirement when one considers the high process temperatures. Pre-heating before welding, therefore, takes a key role. The component is heated precisely to the required process temperature of around 160 to 180 degrees Celsius. This prevents unwanted heating of the material structure in the heat-affected zone, the area directly surrounding the weld. Pre-heating effectively prevents the formation of cracks in the component after welding.
Induction heating is ideally suited for setting up automated production processes. The technology is easy to integrate into the overall process flow and enables the machining of very large part quantities quickly, precisely and safely. Hardening, joining, brazing and pre-heating are examples of applications that benefit from this flexible technology.
Combined with innovative drive and clamping solutions, the MIND-M plus by eldec provides its users with huge increases in productivity for induction hardening, leading to a decrease in overall unit costs. The powerful generator inside plays an extremely important role.
Experts are predicting an increased production of cars with electric motors. Though most of these cars will be hybrids, the increase in production will still pose a challenge to production planners. The question is how to process these larger quantities?
Brazing offers many benefits to every user, including: low heat input, good electric conductivity and permanently leak-tight connections. However, the method of choice is critical. For example, if ovens or gas flames are used, heat transfers into the material relatively slowly. Induction brazing, on the other hand, has many advantages over flame soldering or furnace soldering.
Even though statistics on electric mobility show only moderate growth in automotive markets, the Center of Automotive Management (CAM) predicts a significant upswing in market dynamics from 2020. For Germany and the EU, this means an exponential increase in electric car sales and a fundamental change in drive technologies.
Mass customization – mass producing customer-specific products – is one of the mega trends impacting industrial production today. Automobile manufacturers became early adopters as well as experts of this practice because they quickly realized that buyers want customizable options. A study by puls market research on the significance of customization found that 28 percent of car buyers feel that it is important or very important that a new car differs from standard vehicles and equipment. Now, sophisticated, online software allows buyers to build a custom, dream model with a few clicks, choosing motor specifications, transmission types, assistance systems and countless interior equipment details. Catering to the desires of car buyers and allowing thousands of combinations of options for each model complicates manufacturing because cars have become unique items. Suppliers must produce certain components and parts in many more variants than they did just a few years ago. Furthermore, the life cycle of parts is ever shorter, because technological development is advancing at such a fast pace.
The academic department of Forming and Joining at TU Chemnitz is expanding its systems technologies for research into complex welding, heat treatment, and forming tasks
Since 29 June 2018, the academic department of Forming and Joining at TU Chemnitz has been using a new induction generator that enables the heating of semi-finished goods consisting of several layers of different materials by applying different frequencies in a targeted manner. This may be useful in particular for the production of plated pipes in the chemical industry or in power plants. 62,000 tons of pipes are produced for these sectors per year in Germany alone.