Stefan Junker

Defect reduction in the production of electric drives by downstream compensation and space-resolved inspection

Improving the material efficiency in the production of electric drives is necessary as the electric automotive sector is growing very fast. Here, a method for early defect identification and downstream compensation, which allows defect reduction and consequently waste reduction, is presented. This reduces the waste motor parts (rotor stacks) and decreases the amount of rare earths to be recycled. A new inspection device was developed that allows a space-resolved in-line inspection of single rotor stacks as well as assembled rotors, in the same inspection station. This inspection device was realized as a demonstrator system, which is explained in detail in this paper. The inspection results are used as input for the downstream compensation methods, selective and sequential rotor assembly. Both methods combine stacks that are out of tolerances in such a way that the final rotor is within the specified limitations. Thus, low quality parts form a high quality assembly without having to scrap stacks and magnets.

CESA 3 R: Highly versatile plug-and-produce assembly system

The presented machinery concept CESA3R (Concept for Engineering free, Scalable, Advanced Automated Assembly system for Rapid ramp up) addresses todays challenges in production such as product variety and quantity variation by enhancing versatility. Central elements are function oriented standardized automation devices, which are technically featured with independent structure recognition and self-descriptive capabilities. A precise localization unit combined with a skill based programming concept allows an automatic configuration and program generation. The devices can be arranged at runtime to automate a given assembly task without additional engineering and programming efforts.

Highly versatile plug&produce assembly systems

Due to decreasing innovation cycles, new technologies are implemented into new product ideas continuously faster. At the same time, well established manufacturers of goods are facing highly agile small and medium sized enterprises bringing new and innovative products to the market very fast. While this competition allows customers to select products fitting best to their demand and budget, producing companies are challenged with decreasing product life cycles, a higher product variety, fluctuating demands as well as strong cost pressure. As this so called mass-customization effect is more and more affecting also classical high volume-low variant markets, production systems which provide both, high productivity and adaptability, are required.