New energy vehicle - Innovationsgeist erwünscht
New energy vehicle - Innovationsgeist erwünscht

New Energy Vehicles are here to stay. The production of electric cars, plug-in hybrids and fuel cell vehicles is booming.

Alternative drive systems require new manufacturing processes and therefore new automation solutions. Electric cars are especially characterized by light construction and innovative uses of materials. The passenger compartment is made of carbon fiber reinforced plastic to compensate for the added weight of the electrical components.

These new fiber compounds are a challenge for sensors which we, as long-time partners of the automobile industry, have eagerly taken on. This means you will find optimal solutions for alternative mobility at Balluff.

Application examples

 

 

  • Track carbon fiber reinforced plastic parts

    Track carbon fiber reinforced plastic parts

    The solution

    Rely on our identification solutions when it comes to proper classification of the carbon fiber parts. Now you can see all the data from the cutter, preform and roughening, press and trim steps.

    The data are read out by our Vision Sensors in the system or our rugged hand-held barcode scanners. So you can get the information from all common 1D, 2D and stacked barcodes.

    The features

    • Rugged, industrial-grade design with IP65 protection rating and drop protection up to 2 m
    • Intuitive aiming system with highly visible laser marking
    • Once charged – up to 30,000 read cycles from lithium ion rechargeable battery
    • Wireless versions with Bluetooth for portable use
    Track carbon fiber reinforced plastic parts
    Find suitable products Downloads

    Industry team

    Do you have questions? Would you like a consultation? Our industry team looks forward to hearing from you.

  • Detect carbon fiber reinforced blanks in grippers

    Detect carbon fiber reinforced blanks in grippers

    The solution

    When the trimmed carbon fibers are inserted during the preform process, our ultrasonic sensors check whether the gripper is correctly holding the mat. By doing so they ensure that the carbon fiber blanks are correctly formed. Dust and dirt which could affect photoelectric sensors have no impact on ultrasonic sensors. And in contrast to capacitive sensors, these rugged jacks-of-all- trades simply ignore any electrostatic discharge that might arise.

    The features

    • Generous detection range (25 mm up to 6 m), even for greater object distances
    • Extreme precision with high resolution and no blind zones
    • Insensitive to environmental effects such as dirt or dust
    • Rugged, precise measuring principle, unaffected by color or surface composition
    Detect carbon fiber reinforced blanks in grippers
    Find suitable products Downloads

    Industry team

    Do you have questions? Would you like a consultation? Our industry team looks forward to hearing from you.

  • Reliably monitor the resin injection process

    Reliably monitor the resin injection process

    The solution

    Using our resistant capacitive high- pressure, high-temperature sensors you ensure in advance of the resin injection process that the preform blanks are given their required stiffness. These sensors monitor complete filling of the mold with resin and ensure that the blank joins with the resin.

    Their high degree of ruggedness means long service life, since they withstand high pressures and adhesion forces.

    The features

    • For extreme conditions: stainless steel active surface
    • For pressures up to 150 bar and high temperatures to 180 °C
    • Non-contact and wear-free for long service life and process reliability
    • IP67, IP68 and IP69K protection ratings
    Reliably monitor the resin injection process
    Find suitable products Downloads

    Industry team

    Do you have questions? Would you like a consultation? Our industry team looks forward to hearing from you.

  • Transparency and flexibility in electric motor assembly

    Transparency and flexibility in electric motor assembly

    The solution

    By identifying with RFID you always have the overview of your electric motor assembly because the non- contact technology documents every production step quickly and reliably. Ethernet communication makes the system especially flexible. And with our All-in-One RFID reader it's an extremely economical solution. You eliminate the processor unit, since the rugged read/write head is connected directly to the controller level through the Profinet or Ethernet/IP interface.

    The features

    • Robust die-cast zinc housing for installation directly on metal
    • Diagnostics directly on the equipment using 360 deg. visible LEDs
    • Integrated web server for convenient remote condition monitoring
    • Simple system expansion with integrated 2-port Ethernet switch
    Transparency and flexibility in electric motor assembly
    Find suitable products Downloads

    Industry team

    Do you have questions? Would you like a consultation? Our industry team looks forward to hearing from you.

  • 고정자에서 케이블 돌출 현상 감지

    Detect overhanging wires on the stator

    The solution

    During production of the electric motor you can use the high-resolution light array to ensure that the fine wires of the air coils are exactly positioned. This prevents problems in the following assembly steps and avoids scrap.

    Its wide band of light allows you to monitor a larger homogeneous area than with a traditional through-beam sensor or normal light grids.

    The features

    • Consistent, highly visible 50 mm light array
    • Excellent resolution of 0.01 mm
    • Fast error detection for less scrap
    • Check different aspects at the same time using different measuring modes
    Detect overhanging wires on the stator
    Find suitable products Downloads

    Industry team

    Do you have questions? Would you like a consultation? Our industry team looks forward to hearing from you.