Florian Risch

Production concepts for inductive power transfer systems for electric vehicles

Constantly rising fuel prices more and more encourage the development of innovative electric vehicle concepts. In order to follow this trend and to increase customer acceptance and the practicality of electro-mobility, vehicle concepts with inductive power transfer systems are developed. These have to be integrated into the production lines of the car manufacturers with in each case several adaptations depending on the different types of electric vehicles. Therefore, different vehicle integration concepts and cost-efficient value chains need to be created in order to allow an early start of production to sell such vehicles.

Evaluation of energy efficient joining processes in the field of electric drives manufacturing considering quality aspects

The implementation of green products and matching manufacturing processes increasingly attract public attention. Therefore, the institute FAPS analyzed the joining process as it is identified to be one of the major energy consumers in the context of electric drives manufacturing. The present approach introduces a statistically developed methodology to predict the energy consumption and the resulting connection quality of one of the major, currently available joining techniques. Therefore an analytical model was developed, which was afterwards used to optimize the parameter settings of an industrial cooperation partner.

Handling and Fixation of Permanent Magnets

Due to rapid developments within the family of rare-earth materials innovative electrical machines can nowadays be used as high efficient generators in various power, as well as rugged constructed machines for automobile battery based propulsion in hybrid and full electric vehicles. The production of different motor concepts spread into different design variants and creates complex variations especially regarding the rotor. Deriving from various research projects, the handling of the permanent magnet components is investigated, including the development of new assembly and fixation methods.

Disassembly strategies for recovering valuable magnet material of electric drives

The paper discusses different automation concepts for the disassembly of magnetized magnet bodies from rotors, and for the removal of the bandaging of rotors. In detail three strategies to recover the magnet bodies of rotors will be presented. Furthermore the paper introduces an innovative disassembly machine, which can handle different variants of the targeted magnets, to avoid the troubles during the manual removal of magnetized magnets from rotors with surface mounted magnets. The paper also presents a concept for recovering internal permanent magnets.

Disassembly, recycling, and reuse of magnet material of electric drives

The paper discusses different automation concepts for the disassembly of surface mounted magnets, and for the removal of the bandaging of rotors. In detail three strategies to recover the magnet bodies of rotors will be presented. Furthermore the paper introduces an innovative disassembly machine, which can handle different variants of the targeted magnets, to avoid the troubles during the manual removal of magnetized magnets from rotors with surface mounted mag-nets.

Flexible Automation for the Production of Stators and Rotors of Electric Vehicles

The increasing electrification of the drive train will - sooner or later - lead to significant changes in the value chains for vehicle manufacturers and suppliers, while sales potentials are still uncertain. Due to the currently small number and high diversity of industrial electric motors with higher power and the complex handling of the necessary materials, the processes are based on manual labor content. For the automotive industry high volume production concepts for electric traction motors will be required in the future. Thus, the importance of automated assembly and manufacturing technologies for electric motors moves into focus. In the production of electric motors e.g. the wiring processes of the stators and the magnet assemblies for permanent-magnet synchronous rotors show potential for further process rationalization. This paper presents alternative approaches for the automation of wiring and magnet assembly processes developed at the Institute for Factory Automation and Production Systems (FAPS) at the Friedrich-Alexander-University of Erlangen-Nuremberg.

Optimization approach of Wireless Power Transfer systems for electric vehicles from a process and material perspective

Modern Wireless Power Transfer (WPT) systems for electric vehicles (EVs) have already shown their potential for high-power transfer efficiency in many prototypes and trials. However, WPT for EVs is a particularly demanding application and still in its early commercialization phase. There are still some barriers to overcome for a successful and large-scale implementation of WPT systems to become a preferred method for recharging EVs. For practical application in an EV, power pads need to meet strict automotive requirements (ISO/TS 16949:2009 certification). A thorough material and process analysis must be used to identify and assess failure modes and effects preventatively. In this context, it is the objective of this paper to present an automated test bench approach to precisely evaluate WPT systems with a focus on the process and material perspective.

Laserschneiden in der Elektroblechfertigung

Kurzfassung Die Fertigung elektrischer Antriebe steht auf dem Prüfstand. Bekannte Prozessketten werden auf Grund des Einstiegs der Automobilindustrie grundsätzlich hinterfragt, optimiert, und teils völlig neue Werkstoffe im Stator und Rotor fordern traditionelle Prozesse, wie z. B. das Stanzpaketieren, zunehmend heraus. Obwohl das Laserschneiden von Elektroblechen in vielen flexiblen Produktionen bereits seit Jahren zum Einsatz kommt, liegt die Produktivität im direkten Vergleich noch um einige Größenordnung unter den verfügbaren Stanzverfahren. In der Forschungsgruppe des Bayerischen Technologiezentrums für elektrische Antriebstechnik (E|Drive-Center) am Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik der Friedrich-Alexander-Universität Erlangen-Nürnberg werden daher Rationalisierungseffekte beim Laserschneiden durch neuartige Ansätze erforscht und der Automatisierungsgrad gezielt erhöht.

Effiziente Erstellung, Distribution und Rückmeldung von Werkerinformationen in der Montage

Kurzfassung In der von manuellen Arbeitsplätzen geprägten Montage komplexer und variantenreicher Erzeugnisse mit kurzen Produktlebenszyklen müssen die Mitarbeiter als kreative Leistungsträger bei der Bewältigung der steigenden Anforderungen unterstützt werden. Zu diesem Zweck wird am Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) der Universität Erlangen-Nürnberg die Erstellung, Distribution und Rückmeldung von Informationen in der Montage auf Basis eines durchgängigen Systemansatzes betrachtet. Die hierbei entwickelten Werkerinformationssysteme können einen essentiellen Beitrag zur Beherrschbarkeit der Produktion leisten. Sie unterstützen durch eine didaktisch-psychologisch aufbereitete Informationsdarstellung das eigenverantwortliche und flexible Abarbeiten der Aufträge und helfen so, unter anderem Rüstzeiten zu minimieren, Erfahrungskurveneffekte schneller zu realisieren und technische Änderungen effektiver zu kommunizieren.

Active controllable and flexible winding needle an option to reduce the complexity of needle winding machines and the stress on enameled wire

State of the art needle winding technologies have one thing in common - a stiff, straight or bent winding needle. During the manufacturing process of electrical machines, the used enameled wires are exposed to deformations which decrease the insulation resistance against partial discharge and disruptive discharge. A reduced insulation resistance shortens the product lifecycle. The active controllable and flexible winding needle is able to adapt its form to the mechanical behavior of wire during any deformation and thus to wind wires more gently. In the production of electrical machines the copper filling factor in the slot is often considered key. To provide the needed space for the tools to move through the stator while distributing the windings, the winding tools have to be rather small or the inner diameter of the stator has a minimum whereat the feasibility for needle winding is still present. With the actively controllable and flexible winding needle no more extra axis and other constructions are necessary to fulfill the requirements of a small tool at maximum flexibility.