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.
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.
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.
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.
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.
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.