high voltage technologywith secure connections to the future
STRUNK ensures safe connections in HEV, BEV, FCEV
About 10 years ago we designed the first connection technology for geared motors together with an OEM. From this the E-Traction / Powertrain division developed for geared motors in the “E-Mobility” area, which extends to fully automated production. Furthermore, our applications in the area of HEV, BEV, FCEV include:
- Power distribution (power distribution) via BUS bar on-board networks and power distributors
Connections of connector systems to high-voltage lines
- Butt welded connections and overlapping welded connections from BUSBARS to cables and braids for module connectors of the individual high-voltage storage units
- Connections in the high-voltage on-board network from the battery to the inverter or from the inverter to the electric machine through to the phase connection in the assembly.
- Connections in the ECU’s
- Traction distributor
- Connection technology in the gear motor (phases and star points) as well as connection to current rings
In general, this area involves welding high-voltage connector systems to high-voltage lines (HV lines) with cross-sections from 25 to 120 mm² for cable connector systems or BUS bars and traction distribution systems for four-wheel-driven e-mobility up to a cross-section of 300 mm².
Absolute reproducibility in the connection is of the utmost importance, since there is a risk of fire in the event of a field failure. For this case, we have developed systems for welding under hard solder, which enable fully automatic production including monitoring.
The specially designed STRUNK-MES software ensures individual product-related traceability. This provides the required data by networking the systems in individual production steps within the automated production in an SQL database or uploads the customer-specific data to the customer’s own MES system.
In the field of e-drives from HEV, BEV, FCEV, connections can be made with wound stators or hairpin stators. The wound stators are firmly connected using hot crimping technology and the hairpin stators using brazing solder.
High-voltage cable set and module connector
Cable and non-ferrous metal connections in electric vehicles must be designed for the conditions of high current loads. The contact resistance at the connections must be close to zero. If this is not guaranteed, the resulting heat build-up (hot spots) which then lead to field failure as the resistance continues to rise. The aim is therefore to ensure transmission is as loss-free as possible. In addition, the mechanical holding forces are extremely important here, so that no high-resistance effect or even a loosening of the connection can occur even under mechanical stress and environmental stress. In these cases, our technologies offer you the opportunity to achieve secure and demonstrably long-term stable connections even under high loads.
In the area of high-voltage technology, Strunk develops and manufactures technologies for you for the following areas of application:
- E-traction: everything related to the drive train, e.g. B. Welding the phase connections and star points,
- Connections to stators using winding and hairpin technology,
- Connection technology for rotors,
- Connection technology in assembly (phase connection to terminal board),
- Power Distribution / BUS-Bars / Lead Frames: high-voltage electrical systems, BUS-Bar electrical systems,
- High-voltage storage systems: Development of new technologies for battery cell connectors (HV cable set),
- HV connection technology from high-voltage cables to HV connectors,
- AC / DC charging systems,
- Pyro fuse.
In the area of HV cabling, we can carry out welding under hard solder as an overlapping process or as a butt welding process.
(Individual customer solution as an example)
BusBar welding machine under braze
Flexible manual welding system for connections under hard solder in the field of power distribution. Connections from BusBars to connection elements (HV contacts), BusBars to HV lines and pigtails possible. The narrow design and the tools that can be changed quickly enable the production of busbars with difficult geometries. A flexible STRUNK servo hard solder supply with integrated monitoring can be connected at a wide range of angles on the right and left. Furthermore, a 0° STRUNK SERVO braze feed unit enables different braze widths to be fed through the welding unit. A conversion kit for compacting cables and pigtails up to 120mm² is also available. The facility is via camera or DMC for full traceablitly capable. Can be connected to STRUNK MES or customer MES systems.
Double-head transfer as a semi-automatic for HV contacts
Flexible semi-automatic welding cell with transfer for compacting under brazing solder and welding the compacted wire to a HV contact. By compacting under hard solder and automatically translating the compacted line, the most precise dimensions and reproducibility are achieved. A set-up process for a different HV contact is completed in the shortest possible time by simply exchanging the weld nest. The gripping systems have NOK cutters and the system is camera or DMC capable for full traceability. Can be connected to STRUNK MES or customer MES systems. Area of application from 6-95mm².
Welding cell with S-MMD3-150 for connecting HV cables to terminals, bus bars and HV contactors
Manual welding cell with automatic STRUNK SERVO brazing alloy feed built on quick-change couplings. Tools on quick-change plates for quick conversion to another application. The facility is camera or DMC capable for full traceability.
Semi-automatic welding system for stator production
Semi-automatic welding system for stator production with multiple gun system for different welding tasks (hot crimping and welding under hard solder). The facility is camera or DMC capable for full traceability. Can be connected to STRUNK MES or customer MES systems.
Double-head compacting plant under hard solder for the production of different cross-sections
Customer-specific semi-automatic for compacting under hard solder of different cross-sections for later welding on BUSBAR systems. The production takes place in the ONE PIECE FLOW sequentially with a subsequent automatic welding process. The compaction under hard solder enables the welding process in tight spaces and multiple welding points. The facility is camera or DMC capable for full traceability.
Double head transfer as a semi-automatic for HV contacts
Flexible semi-automatic welding cell with transfer for compacting under brazing solder and welding the compacted wire to a HV contact. The most precise dimensions and reproducibility are achieved by compacting under hard solder and automatically translating the compacted line. A set-up process for a different HV contact is completed in the shortest possible time by simply exchanging the weld nest. The gripping systems have NOK cutters and the system is camera or DMC capable for full traceability. Can be connected to STRUNK MES or customer MES systems. This system also has an optionally selectable contact part feed.
Fully automatic system in turntable design for BusBar connections under hard solder with robot
Special system as a fully automatic device for power distributors (BUSBARS) to contacts. The components are handled and positioned by robots mounted on the ceiling. The facility is camera or DMC capable for full traceability. Can be connected to STRUNK MES or customer MES systems.
Fully automatic machine for welding phase connections and star points on stators
The system is designed for standing stators on tool carrier systems. It has a STRUNK servo rotary / lifting unit as well as a portal system with servo X / Y / Z infeed. The 4-axis machine can thus reach and process all positions on a pallet.