E-Mobility - DEPRAG

E-MobilityASSEMbly SolUtioNS

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KEy CoMPoNENtSe-mobilitY

• Controlandpowerelectronics

-Inverter -OBConboardcharger -BMSbatterymanagementsystem -IGBT

• Bodyinwhite,bodyworkchassis

• Electricmotorsandgears

• Batterypack

• Batteryhousing

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E-mobility imposescertain requirementson theassemblyprocess: topprocess reliability forsafety-relatedcomponents,highflexibilityduetothewiderangingvariety,requirementsfortraceabilityandtargeted reliable electro-static discharge (ESD capability) of system components. In addition, thesecomponentsrequireanassemblyenvironmentwhichfulfilstheguidelinesoftechnicalcleanlinessandalsoscoreshighlyonergonomicandsafetyaspects.

The complexity of the different tasks is a challenge to a budget-friendly approach. The solution:DEPRAG – your innovative partner in the field of E-mobility.

Fromcomponentsandmanualworkstations,up tosemior fully-automaticassemblysystems,weprovideflexibleassemblysolutionsforallstagesofexpansion,whichcanallbeadaptedtothecurrentmarketsituationatanytime.Thisflexibilityspecificallycounteractsplanninguncertaintiesandenablesreactiveresponsestochangingrequirements.

Products for all stages of expansion, from one source, available internationally!

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ASSEMblybatterY PaCK

Theinnovativehighvoltagecomponentsofanelectricvehiclepre-sentunseenchallengesforproductionassembly.Theintegrationofhighvoltagecomponentsdemandsradicallynewsolutions.Inaddi-tion,theissueofhighvoltageintheassemblyprocessneedstobetakenintoaccount.Electric vehicles have significantly higher voltages (up to 800 voltdirectcurrent).Thisrequireshighersafetymeasuresforoperatorsintheassemblyprocess.

Duringbatteryassembly,thecellmoduleisassembledfirst.Thein-dividualbatterycellsarestacked,placedinthebatteryhousingandconnected to thebatterymanagement system. In a next step thecurrentcollectorisconnectedtothepowersupply,thewiringische-ckedandthehousingclosed.Subsequently,thepowersupplyandcontactsareconnectedbeforethefinishedmodulesaretested.Theindividualcellmodulesarefixedtoafloorelementviacontactrailsandassembledwith fasteners.Finally,electronicboardsandsealscanbeattached.

•Installationofthemodulerequirescompletetraceability.

•Thebatterysizeandresultinghighnumberofassembliesisusuallyautomatedandhasshortcycletimes.

•Avoidanceofparticlecontamination.

•Safetyforoperators:contactwithlivepowercircuitscancauseserious,evendeadly,injuries.

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DEPRAGinsulationconcept:•specialceramicandsyntheticparts•protectsagainstvoltageofupto1000volts

Insulatedscrewdrivingtools

Multi-spindleversionforshortcycletimes

Screwfeedingsystemstoincreaseproductivity:stepfeedingsystemeacystepfeed

Gripperjawstoavoiddroppingthescrew

Safetyatwork:Insulatedsolutionsprotectboththeopera-torandtoolfromelectricshocks.Theappli-cablestandardsaremete.g.

•ISO6469-3Electricallypropelledroadvehicles–Safetyspecifica-tions–Part3:Electricalsafety

•DINENIEC60900(VDE0682-201)Liveworking;Handtoolsforuseupto1000VACand1500VDC

andmanymore.Ofcourse,weworktoyourspecificationsandcan reactflexibly to thestandardsrequiredinthefieldofE-mobility.

Traceability:Adaptive screwdrivingprocedures, togua-ranteecompletetraceability.

Technicalcleanliness:DEPRAGCleanFeedconceptwithscrewdri-ving functionmodulewith vacuumsuctionandscrewfeedingviastepfeedingsystem.

ASSEMblyPoWer eleCtroNiCS

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Technical cleanliness is of paramount importance for assemblingelectronic components andmodules in the fieldof power electro-nicsandparticularlyinthefieldofhighvoltagecomponents:particlecontaminationcanquicklyleadtoinsulationerrors,mechanicalcon-tactblockages,underminingorinterruptionoflightbarriersforhighlysensitivecomponentsinpowerelectronics.

Thecriticalparticlesmaybecreateddirectlywithintheprocess,duetoboththehighnumberofcomponentsintroducedintotheprocessandtheassemblystepsthemselves.Conductiveparticlesinparticu-larmaycausehighvoltagearcflashesandshortcircuits.

Duetothecomplexdesignofindividualcomponentstheoperatormayoftenhavetodealwithscrewpositionswhicharedifficulttoaccessandwhichmustbeassembledinaspecificsequentialorder.

•Technicalcleanliness

•Difficulttoaccessscrewpositions

•Workersafety

•Safety-criticalassembliesofcategoryA

•Correctsequentialorderofassemblies

•ESDdesign

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technical cleanliness

DEPRAG EC screwdriving technology: •freelyprogrammablescrewtightening•torque,speedandrotationcanbeadjustedindividuallytotheassemblytask

•hightorqueaccuracy•comprehensivemonitoringfunctions•ESDcapable•ergonomic•documentationavailable

DEPRAGparticlekiller:dirtparticlesaretargetedandremovedfromtheconveyor

DEPRAG Feed Module DFM with vacuum:•fatigue-freeworking•optimisedcycletime•technicalcleanliness

DEPRAG EC cordless tools:•flexible•documentationavailable•userfriendly•highperformance•cordlesscommunication

For difficult to access screw positions

Lowabrasion,gentlefeedingwiththeDEPRAGswordfeeder

VacuumsuctionDEPRAGeacystepfeedstepfeeder

ESDcapability:ESDcapablescrewdriversandaccessories,e.g.feedhoses.

Userfriendly:Ergonomicscrewdrivingtoolsforcomplexscrewpositions.

Traceability:Completetraceabilityofthescrewdrivingprocess.

Technicalcleanliness:WiththeDEPRAGCleanFeedconceptinallprocessingsteps–fromscrewhandlingandfeedinguptoscrewassembly–avoid,reduceandremoveparticles.

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ASSEMblyComPoNeNtS

UsuallyscrewjointsofthecategoryAinaccordancewithVDIstan-dard2862areusedfortheassemblyofelementsintheautomotiveindustry.Processreliabilityisofutmostimportanceandallproces-singstepsmustbedocumentedandmonitored.

Theassemblyprocessforbatterymoduleorpowerelectronicswithawidevarietyofcomponentsishighlycomplex:numerousscrewsmustbeassembled in thecorrectorder toguaranteeaconsistentpre-loadforce.

Withinlightweightconstruction,especiallyinthefieldofE-mobility,aluminium,other lightweightmetalsandsyntheticmaterialsare in-creasingly used.Widely varying torques are commonly a result ofthefrequentlyemployeddirectassemblies.Duetodifferentmaterialcharacteristics,settlingconditionscanalsovary.Asthesearepre-dominantly conductive connections and conductivitymust be gu-aranteed, adaptive screwdrivingprocedures are recommended forreliabledetectionoftheseatingpoint.

•Settlingconditionswhenusingvaryingmaterials.

•Screwtighteninginaprescribedordertoguaranteeconsistentpre-loadforce.

•Safety-criticalassemblyofcategoryA.

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Digitalassemblyguidesforoperators:error-freeassemblyandtraceabilityofallprocessingsteps,MEScommunication

Topprocessreliability:

•ScrewdrivingprocedureDEPRAGCFC ClampForceControl:zeroerrorproduc- tionandtraceability.

•Positioncontrol:correctsequenceof screwsforoptimumquality.

•Processmonitoringwithcamerasystems.

•Completedocumentationofproduction data.

•VisualoperatorguidancewithDEPRAG OperatorGuidanceDOG.

EC-Servo technology with DEPRAG CFC Clamp Force Control

Process monitoring

Positioncontrolstand(PKS),positioncontrolgantry(PKP),camerasystems

Process visualisation with DEPRAG operator Guidance

Adaptive screwdriving procedure DEPRAG CFC Clamp ForceControl: despite fluctuating tightening torques, the procedureguaranteesreliabledetectionoftheseatingpointandensuresaconsistentfinalpositionforthesubsequentfinaltighteningresul-tinginaconstantpre-loadforce.

ASSEMblyboDYWorK CoNStrUCtioN aND batterY HoUSiNG

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Lightweightconstructionand thesubsequentweightsavings invol-vedareamongstthegreatestdrivingforcesfor innovationinbody-workconstructionandbatteryhousingproductionwithinE-mobility.As thebattery isheavy, theweightof thebodyworkand furnishingsmustbekeptlow.Lightweightconstructionmaterialsareutilisedtore-ducethenetweightofthevehicleandtominimizeenergyconsumption.

Assemblyandjoiningtechnologyaregoingthroughradicaltransfor-mationduetolightweightconstruction–thematerialmixdeterminestheprocessandrequiresthehighestpossiblelevelofflexibilityfromthefasteningsystem.

Theachievabletravelrangeisthedecisivefactorwhenpurchasinganelectricvehicle.Lightweightconstructiontoreduceenergyconsump-tion isacrucial issuewithin thefieldofE-mobility.Thematerialofthebodyworkpresentsachallengetotraditionalassemblymethods.Whether aluminium design or a sophisticated multi-material mix,DEPRAGhasthesolution.

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Ourmanyyearsofexperienceandthecontinualexpansionofourglo-bal knowledge have placedDEPRAG as a front runner and leadinginnovatorinthedevelopmentofFDSsmarttools.Ourpatenteddrivetechnologyisuniqueinthemarketandhasbecomeagamechangerintheindustry.Hundredsofsystemsoperatingatautomobilemanufactu-rersaroundtheworldareimpressiveevidenceofthis.

Theselectionofthecorrectfasteningtechnologyforlightweightcon-structionisofutmostimportance.Flowdrillscrewassembliesarethetechnologyofchoiceforlightweightbodyworkconstructionintheauto-mobileindustry.TheadaptiveassemblyunitADAPTIVEDFScombinesEC-Servo screwdriving technology with EC-Servo feed technology.This enables automatic piercing detection throughout the flow drillassembly, independent from screw and component tolerances. Theprocessingparametersareadjustedautomaticallyandtheprocessingsequence is continually optimised. The screwdriving systemcanbeeasilyconnectedtoarobot.Therearenocomplicatedandcostlypa-rameteradjustments.

•Topprocessreliability

•Shortestpossiblecycletime

•Optimisedfunnelforming

•Eliminatesthreaddamage

•Lowstressonscrewandcomponent

•Minimumset-uptime

•Readyfornewmaterials,fastenersandjoiningmethods

ADAPtiVE DFS DEPRAG FAStENiNG SyStEMScrewdriving system for lightweight construction assemblies

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Fromhighlyautomatedlarge-scalesystems,fullyautomatedassemblylines,standardassemblyunitsrightthroughtosemi-automatedrelia-blemanualworkstations,weofferanenormousrangeofautomationsolutionsforE-mobilityapplications.

•Processreliability

•Flexibility

•Technicalcleanliness

•ESDcapability

•Ergonomics

•Traceability/MES

High flexibility specifically counteracts planning uncertainties andenablesreactiveresponsestoconstantlychangingrequirements.

DEPRAG screwdriving and automation solutions fulfil all assemblyrequirementsforE-mobility:

Please contact your DePraG advisor for more information. We will find the most suitable solution for your assembly process!

SCREWDRiViNG AND ASSEMbly SyStEMS

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DEPRAGCockpitisthenewdigitalservicefacilitatinganeasyintroductiontotheinterconnectedfactory.UsingtheDEPRAGCockpit,theoperatorisabletomoni-toranynumberofvariousscrewdrivingcontrollers,regardlessofthemanufacturer.

Thesoftwaregives fullaccess toproductiondata fromvariousassembly lines.TheDEPRAGCockpitasa focalpointcollectsdata fromacompany’svariousfactorylocations,theirproductionlinesandconnecteddevices.

•Softwareforscrewdrivingandassemblytechnology•Reliableproductiondataacquisition•Detailedcapacityandusagestatistics•Processmonitoringandnotifications•Analysisandtrenddetectionwithsystemmessages

DEPRAG CoCKPitiNterCoNNeCteD SCreWDriviNG SYStemS – it’S eaSY WitH DePraG CoCKPit

the DePraG group has production facilities in Germany, the Czech republic and China, as well as distribution and service companies in France, mexico, Sweden, the USa and the UK. our network of exclusive partners in all the main industrialised countries around the world means that we are always on hand to assist our global customers.

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Your global partner for e-mobility

E-Mobility - DEPRAG

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