Battery Technology Show
22nd – 23rd October 2019 - Ricoh Arena, Coventry
TRUMPF stand number: 30
TRUMPF focusing on electromobility and Industry 4.0
High-tech company TRUMPF sees major opportunities for its business and for industry as a whole in the two megatrends of Industry 4.0 and e-mobility. “The mechanical and systems engineering industry can reap big benefits from connectivity in industry and e-mobility,” said Mathias Kammüller, Chief Digital Officer at TRUMPF. “Two key areas are connected manufacturing, as the next stage of technology on the shop floor, and future mobility. These two factors will help safeguard jobs in development, manufacturing and application engineering – and even create new ones,” he said. Kammüller also noted that digitally connected lasers will play an essential role in the transition from vehicles powered by internal combustion engines to all-electric vehicles. He also noted that lasers were the key to making the production of electric vehicles cost-competitive in the first place.
Growing demand for manufacturing methods for electric vehicles
TRUMPF has witnessed a surge in demand for manufacturing technologies in the realm of e-mobility. Battery manufacturing already makes up 10 percent of TRUMPF's turnover in the automotive sector, a figure that is continuing to climb. The company has already sold more than 500 lasers worldwide for use in battery manufacturing. “We have the right manufacturing methods to enable the commercially viable production of key components of future mobility solutions: lasers really are the only technology that can offer such a flexible, highly productive way of mass-producing batteries, high-power electronic systems and electric drives,” said Christian Schmitz, Chief Executive Officer Laser Technology at TRUMPF. Finding an affordable means of producing electric vehicles by the millions requires robust manufacturing methods that can be scaled up quickly from today's relatively low volumes to full-scale mass production.
Laser technology for efficient mass production of electric motors
A series of laser techniques can weld all the seams on an electric motor in just one minute. “TRUMPF’s welding process for what they call the ‘hairpins’ is just one of the techniques used to make the production of electric motors faster, more reliable and more economical. It eliminates the costly and time-consuming process of winding thick copper wire arounds the coils of powerful electric motors. And that makes it much easier to produce them in bulk,” said Schmitz. The hairpin method involves using a compressed-air pistol to fire a rectangular copper wire, similar to a hairpin, into a slot on the side of the motor. The protruding parts of the wire are then twisted together and welded using a laser.
Digitalization for reliable battery manufacturing
TRUMPF technology also plays a key role in manufacturing batteries for electric vehicles. The batteries consist of multiple layers of wafer-thin copper and aluminum foils that are cut to size using lasers. After adding liquid electrolyte, the battery is welded shut with a cap. It is essential that the welds seal the cell completely, because battery failure during operation could pose a risk of fire and injury. From the battery cells and battery modules to the battery pack, all the welding is carried out using a laser. The laser systems feature sensor systems as well as a software program that connects them to a cloud solution. The sensors provide data for quality assurance and documentation purposes, but they also help control the welding process itself. “One problem for battery manufacturers is that they can't test whether a battery actually works until the very end of the manufacturing process. They need the process to be monitored continuously to ensure that the battery comes out the other end working properly,” said Schmitz.
TRUMPF expands its own digitalization capabilities
“Our lasers for the automotive sector are a good example of how important digital transformation is to TRUMPF. To ensure our own production processes remain fit for the future, TRUMPF are constantly expanding their in-house digitalization efforts,” says Mathias Kammüller. “TRUMPF already has over 500 employees working on more than 30 digital transformation projects. That’s helping us to improve efficiency, cut costs, and boost our competitiveness.”