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Stator/rotor welding facility

KEY DATA:

  • Beckhoff Industrial PC control unit with NC-I
  • 15“ touch panel
  • Beckhoff TwinSAFE safety technology
  • Beckhoff Servo drive technology
  • 8 plasma welding units
  • Hydraulic force-displacement measurement systems
  • Contactless printing system
  • SQL database system for complete tracking
  • Control stations with links to the database
  • Complete article assessment
  • Fieldbus EtherCAT

OUR SERVICES:

Engineering

  • Project planning
  • Risk evaluation and safety assessment according to Machinery Directive EN 13849
  • Performance specification
  • Interface specifications
  • Welding process
  • Wiring diagram
  • Operating manuals, servicing plans

Software development

  • PLC programming according to IEC 61131-3
  • Visualisation

Control installation

  • Construction of control cabinet
  • Installation and commissioning of the facility
  • Process optimisation together with the customer

Handover

  • Training and manufacturing support

Short project description:

The facility manufactures stator and rotor laminated sheet packages for the electric powertrain of the Renault Z.E. The electric motor of the Kangoo Rapid Z.E. has an output of 44kW/60 HP with 10,500 1/min. The maximum torque of 226 newton metres is available upon start-up.

The sheet packages are weighed using the integrated scales to ensure that the correct number of sheets is used. With the help of the filling guide, the sheets are positioned in the tool of the facility. Once the fully automated manufacturing process commences, the sheet package is compressed and measured behind the closed safety door. Any deviation from the required length is shown to the operator in the number of sheets (+/- sheets). Once the package has been measured successfully, the seams are welded using a generated G-code (interpolated line movements) and a rotational and welding axis. During the welding process, all welding streams of the individual burners, forces, speeds, etc. are recorded and saved in the SQL database. After the welding process, a gripper system places the welded package in the cooling section. At the control station, the packages are measured and the reference dimensions are added to the article data and saved in the database by a PC station.