As a mechanical engineering company, EMAG is making an important contribution to establishing electromobility: The specialists are developing the production technology that can manufacture central components of the electric motor – on a turnkey basis. A new production line for the rotor shaft of electric cars used by a German components supplier illustrates their approach. The solution was delivered at the end of last year. Here we have a conversation with Andreas Bucher, Key Account Manager at EMAG, and Michael Ihring from EMAG Systems about the reasons for this cooperation.
Whenever containers are lifted by trucks, large excavator shovels are swiveled or heavy containers are tilted at production plants, powerful rotary drives are to thank! The number of application examples for this technology is almost unlimited. As market leader in this sector, HKS Dreh-Antriebe GmbH with headquarters in Wächtersbach, Hesse relies on vertical hobbing machines from EMAG Richardon – major gearing is created with their help. These specialists have recently acquired a new machine of this type for their production site in Neukirch, Saxony. In the following interview, HKS Production Manager Mario Vogt explains why they made this investment decision and what technological challenges stand out in this process.
High-strength materials, complex geometries, large unit volumes—the production of turbocharger shafts is one of the most challenging tasks in automotive manufacturing. With its new turn-key production system, EMAG has developed a holistic and complete solution. How exactly does it work?
One aspect that is often left out of the discussions about e-mobility is the corresponding transformation in car production: Planners must establish new solutions that enable efficient and holistic manufacturing of “e-components” in significantly higher unit volumes. EMAG Systems is prepared for this!
Exactly 1,223 innovations saw the light of day in the automotive industry last year—at least that’s according to a count conducted by the Center of Automotive Management and the consultancy firm PwC. About 27 percent of these innovations pertain to driver assistance and safety systems—one in five belongs to the field of engine construction. Considering the corresponding automotive production, one trend that has been going on for years still holds true: The pace of change is always increasing as the requirement for more flexible production continues to increase. It is important that new parts and components can be produced efficiently, and defect free using existing product solutions.
Electric power steering has become standard in the manufacturing of automobiles. The technology guarantees very precise steering support for every type of vehicle, high-end driving comfort, and lower energy consumption in the steering system, which has a positive effect on the car’s CO2 consumption.
A continued rise in the demand for customized systems and integrated solutions was predicted back in 2014 by a survey of German manufacturers of plant and machinery, in a study on the future perspectives for the industry in Germany. This is not surprising given the huge “Industry 4.0” trend, as extensive automation in the form of customer-specific system solutions is a fundamental prerequisite for the digitalization of production facilities. The machines used then form an integrated system that production planners can control from a central point. Moreover, many companies need to respond ever more quickly and flexibly to technological developments. Numerous different versions of parts and fluctuating unit volumes are typical for small and medium-sized production companies in the automotive industry.
The EMAG Inverted Spindle Pick-Up Lathe process provides for a significant improvement in accuracy versus that of a sub-spindle lathe.
Lathes with sub-spindles pass a part from one rigid work holding system to another. This does not allow for any misalignment of the two spindles. The first spindle cannot release a part until the second spindle has a secure grip on it. Allowing for mismatches on a split turned dimension such as a bore. The accuracy and quality of the workpieces that are produced from this system are compromised because of this process.
CVT transmissions are becoming increasingly popular in the American and Asian markets. The technology improves driving comfort as the car shifts gears more smoothly. A critical part of manufacturing these transmissions is the creation of the CVT components like shafts and disks (“pulleys”) that need to be hard machined with extreme precision– all as part of a multi-stage process that uses various turning centers and grinding machines.
When a leading tier 1 automotive manufacturer came to EMAG and asked us to meet their goals and needs for new differential lines, we had our work cut out for us. One of the unique promises made by EMAG is the company’s ability to achieve each customer’s needs. With this customer, their needs/goals included: